Komatsu Wheel Loader WA250-1LC Operation & Maintenance Manual SN A65001 and up - PDF DOWNLOAD

CEAMW18021 REPLACES SEAMU418KDlO

WA2504

Lc

WHEEL LOADER

SERIAL NUMBERS

WA250-ILC

A65001 and up

This material is proprietary to Komatsu Dresser Company and is not to be reproduced, in accordance with written authorization from Komatsu Dresser Company.

used, or disclosed except

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication.

It is recommended that customers contact their distributor for information on the latest revision.

MAR 94

COPYRIGHT 1994 KOMATSU DRESSER COMPANY

PRODUCT

PUBLICATIONS

INFORMATION

VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAIlABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS.

SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS IN FOREIGN LANGUAGES.

THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).

FORM NUMBER

DESCRIPTION PARTS BOOK - PAPER: Engine and Chassis . . . . . . . . . . . . .

...

BEPBW18021

PARTS BOOK - MICROFICHE: BEPMW18021

Engine and Chassis . . . . . . . . . . . . .

OPERATION

& MAINTENANCE

Chassis English

MANUAL:

.. ..............

...

CEAMW18021

SHOP MANUAL: Chassis .......................................................

CEBMWl8020

Engine: SET (Includes the following manuals) ............................

Shop Manual ...........................................

Specifications Manual .....................................

Trouble Shooting & Repair Manual ............................

CEBM610001 CEBM61 OSHO CEBM61 OSPO CEBM61 OTRO

SAFETY MANUAL

._................_................................

1085 883 R3

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IF THE PIPS SYSTEM IS NOT AVAIlABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED, FORM KDCSlB, SHOWN ON THE REVERSE SIDE OF THIS PAGE.

PUBINFO.KOM

042093

REQUISITION

FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

COMPLETE FORM

Komatsu America International Company 440 North Fairway Drive

AND RETURN TO -

Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887 COMPANY NAME

SHIP TO

ä

ATTN. STREET ADDRESS

TYPE or PRINT ONLY

CITY, STATE, ZIP CODE COUNTRY I

I

PHONE NO.

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IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), SERIAL NUMBER MUST BE SHOWN.

QTY.

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PARTS BooK PUBLICATION P-Paper DESCRIPTION & M-Microfiche

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CURRENT PRICES WILL BE CHARGED

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FOREWORD

FOREWORD

This manual provides rules and guidelines, which will help you use this machine safely and effectively.

Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor if you are the owner or end user or from Komatsu Dresser Co. if you are a distributor.

If you sell the machine, be sure to give this manual to the new owner.

Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor if you are the owner or end user or consult Komatsu Dresser Co. if you are a distributor for the latest available information on your machine or for questions regarding information in this manual.

A

WARNING! Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operators and maintenance personnel must read this manual thoroughly before operating or maintaining this machine. This manual should be kept near the machine for reference and periodically reviewed by all personnel who come across it. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not performed in the manner described in this The precautions and manual. procedures given in this manual apply only to the intended uses of the machine. If you use the machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual.

NOTICE:

Komatsu Dresser Co. delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If the machine has been purchased in another country or purchased from someone in another country, it may lack certain safety features and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable regulations and standards of your country, consult your local distributor or Komatsu Dresser Co. before operating the machine.

Operation, inspection, and maintenance should be carefully carried out, and safety must be given first priority. The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations.

Some photographs from your machine continually reflected manual’s content is

and illustrations are different as technical improvement is on it. Revision to up-todate performed in later editions.

This operation & maintenance manual may contain attachments and optional equipment that is not available in your area. Please consult your local Komatsu Dresser distributor for those items you may require.

Materials and specifications without notice.

are subject to change

o-1

INTRODUCTION

SAFETY INFORMATION

Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.

To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance.

To identify safety messages in this manual and on machine product graphics, the following signal words are used.

A A

o-2

DANGER! - This word is used on safety messages and product graphics where there is a high probability of serious injury or death if the hazard is not avoided. These safety messages and product graphics usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the machine.

WARNING - This word is used on safety messages and product graphics where there is a potentially dangerous situation, which could result in serious injury or death if the hazard is not avoided. These safety messages and product graphics usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the machine.

A

CAUTION! - This word is used on safety messages and product graphics for hazards, which could result in minor or moderate injury if the hazard is not avoided. These safety messages and product graphics might also use this word for hazards where the only result could be damage to the machine.

NOTICE - This word is used for precautions that must be taken to avoid actions, which could shorten the life of the machine.

Komatsu Dresser cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety message in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact your local distributor if you are the owner or end user or Komatsu Dresser Co. if you are a distributor.

INTRODUCTION

BREAKING IN THE NEW MACHINE

Each machine is carefully adjusted and tested before shipment. However, a new machine requires careful operation during the initial 100 hours as indicated by the service meter.

If a machine is subjected to unreasonably hard use at the initial operation stage, the potential of performance will prematurely deteriorate and the service life will be reduced. A new machine must be operated with care, particularly with regard to the following items.

During breaking in: l

After starting, let the engine idle for 5 minutes to allow proper engine warm-up prior to actual operation.

l

Avoid operation speeds.

l

Avoid sudden starts or acceleration, unnecessarily abrupt stops and sharp steering except in cases of emergency.

with

heavy

loads or at high

l

At the first 250 hours of operation, the machine should be maintained in the manner described in Section 3 “MAINTENANCE�. In addition: 1) Replace the transmission oil filter element.

2) Replace the engine oil filter cartridge and oil.

3) Check and adjust the engine valve clearance.

*

If the machine is delivered without any cooling water in the radiator, flush the cooling system with ample clean water to clean the system, then fill the radiator with cooling water.

*

When replacing oil filters elements (cartridges), check their interiors for dirt and dust. If heavily collected, check for possible cause before starting operation.

*

Hours of operation are indicated by the service meter.

o-3

INTRODUCTION MACHINE AND ENGINE SERIAL NUMBERS When calling for service of a mechanic or when making a replacement parts order, be sure to give your distributor the machine and engine serial numbers as well as the service meter reading before mentioned. These numbers are found on the number plates shown in the following figures.

0

Location of the machine serial number plate It is located on the center right side of the front frame.

0

Location of the engine data plate It is located on the right side of the engine timing gear box when seen from the fan side.

*

o-4

The engine data plate, shows specific information about your engine and provides the information for ordering parts and service needs.

INTRODUCTION QUICK REFERENCE INFORMATION MACHINE MODEL NAME & MACHINE SERIAL NO.

ENGINE MODEL NAME & ENGINE SERIAL NO.

DISTRIBUTOR’S NAME:

DISTRIBUTOR’S ADDRESS & TELEPHONE NO.

NOTES OR REMARKS:

PERIODIC SERVICE

DATE

ITEM

SERVICE METER READING

DELIVERY PERIODIC PERIODIC PERIODIC

CONSUMABLE PARTS

PART NO.

PART DESCRIPTION

QTY.

o-5

CONTENTS DESCRIPTION

PAGE

FORWARD......................................................................

O-I

INTRODUCTION SAFETVINFORMAiidN’::::::::::::::::::::::::::::::::::::::::::::::::: BREAKING IN THE NEW MACHINE . . . . . . . . . .

MACHINE AND ENGINE SERIAL NUMBERS . . .

QUICK REFERENCE INFORMATION . . . . . . . . .

CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY PRECAUTIONS

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o-2 o-2 o-3 O-4 o-5 O-6

-- SECTION 1

GENERALPRECAUTIONS ............................................................

PERSONNELPRECAUTIONS .......................................................

MACHINE PRECAUTIONS ..........................................................

l-2 l-2 l-2

OPERATION.......................................................................

BEFORESTARTING ....................................................

START-UP ...........................................................

GENERAL OPERATING PRECAUTIONS ......................................

DRIVING THE MACHINE .................................................

OPERATINGTHEA~ACHMENTS ..........................................

PULLING/TOWING .....................................................

SHUTDOWN ..........................................................

1-3 l-3

MAINTENANCE .......................................................

GENERAL MACHINE PRECAUTIONS GENERALWORKPRECAUTIONS . ..:::::::::::::::::::::::::::::::::::: ATTACHMENTS ....................................................

BRAKES.. ........................................................

CAB/ROPS .......................................................

COOLING ELECTRICAL’:::::::::::::::::::::::::::::::::::::::::::::::::::::: ENGINE ..........................................................

FUELSYSTEM .....................................................

HYDRAULICS ......................................................

TIRESAND RIMS ...................................................

TURBOCHARGER.. .................................................

VITON SEALS ......................................................

l-4 l-4 l-5 l-6 l-6 1-7

. . . .

. . . . . . .

. . . .

. . . . . .

. . . .

SAFETY PRODUCT GRAPHICS AND LOCATIONS ..........................................

BEFORE CARRYING OUT MAINTENANCE .............................................

l-7 l-7 l-8 1-9 l-9 l-9 l-9 l-10 l-10 l-11 l-11 l-11 1-11 1-12

1-13 l-25

OPERATION -- SECTION 2 GENERALVIEW

.._....._._.........................._................_.............

INSTRUMENTS AND CONTROLS . . . . . . .

MONITOR PANEL . . . . . . . . . . . . . . . .

CHECK MONITOR LAMP GROUP .

CAUTION MONITOR LAMP GROUP METER GROUP . . . . . . . . . . . . . .

WARNING LAMP . . . . . . . . . . . . .

SYSTEM CHECK . . . . . . . . . . . . .

CHECK MONITOR LAMP GROUP .

Brake Oil Level Monitor . . . . . . .

O-6

. . . . . . . .

............

... ....... ..

.......... ..

2-2 ....... ....... ....... ....... ....... ....... ....... ....... .......

2-3 2-3 2-3 2-3 2-4 2-4 2-4 2-5 2-5

Engine Oil Level Monitor ......................................................

Coolant Level Monitor ........................................................

CAUTION MONITOR LAMP GROUP ...............................................

Battery charge monitor .......................................................

Fuellevelmonitor ...........................................................

Brake oil level monitor ........................................................

Engine oil pressure monitor ....................................................

Coolantlevelmonitor .........................................................

Brake servo pressure monitor ..................................................

Coolant temperature monitor ..................................................

Torque converter oil temperature monitor .........................................

Ground driven steering monitor - if equipped ......................................

METERGROUP .............................................................

Parking brake pilot lamp .....................................................

Pilot lamp for working lamp ...................................................

Transmission cut-off selector pilot lamp ..........................................

Ground driven steering pilot lamp ...............................................

Engine cooling water temperature gauge .........................................

Torque converter oil temperature gauge ..........................................

Fuelgauge ...............................................................

Turn signal pilot lamp .......................................................

High beam pilot lamp .......................................................

Speedometer ..............................................................

Servicemeter .............................................................

SWITCHES.. ..................................................................

WORKING LAMP SWITCH ......................................................

STARTING SWITCH ..........................................................

HAZARD LAMP SWITCH .......................................................

HORNBU-I-TON ............................................................. ..........................................................

LAMPSWITCHES..

Lampswitch ..............................................................

Turn signal lever ...........................................................

Dimmer switch TRANSMlSSlONC~T:~~~~~~~~~~R~~li~~:::::::::::::::::::::::::::::::::::::: El-HERSTARTSWITCH .......................................................

FRONTWIPERSWITCH .......................................................

REARWIPERSWITCH ........................................................

WINDOW WASHER SWITCH ....................................................

FRONT FLOOD LIGHT SWITCH .................................................

ACCESSARYSWITCH .........................................................

ROOM LAMP SWITCH ........................................................

CIGARETTE LIGHTER .........................................................

LEVERSAND PEDALS ...........................................................

DIRECTIONALLEVER .........................................................

SPEED CONTROLLEVER.. ....................................................

SPEED CONTROLLEVER STOPPER.. ............................................

STEERING COLUMN TILT LEVER ................................................

ACCELERATOR PEDAL ........................................................

BRAKE PEDALS .............................................................

Right brake pedal .........................................................

Left brake pedal ..........................................................

LlFTARM CONTROLLEVER ....................................................

BUCKETCONTROLLEVER .....................................................

WORK EQUIPMENT CONTROL LEVERS LOCK ......................................

PARKING BRAKE LEVER ......................................................

WORK EQUIPMENT CONTROL LEVER ............................................

MON-LEVERTYPE .........................................................

CAB DOOR HOLD OPEN LOCK - IF EQUIPPED ........................................

AIR CLEANER SERVICE INDICATOR .................................................

FRAME LOCKlNG BAR ...........................................................

ENGINE SIDE DOOR LOCK .......................................................

2-6 2-6 2-7 2-7 2-8 2-9 2-9 2-9 2-9 2-l 0 2-10 2-10 2-11 2-11 2-12 2-12 2-12 2-l 2 2-l 3 2-13 2-13 2-13 2-14 2-14 2-15 2-15 2-16 2-16 2-16 2-17 2-17 2-17 2-l 7 2-18 2-18 2-19 2-19 2-20 2-20 2-20 2-20 2-21 2-22 2-22 2-23 2-23 2-23 2-24 2-24 2-24 2-24 2-25 2-25 2-26 2-26 2-27 2-27 2-28 2-28 2-28 2-29

o-7

CONTENTS MAIN CIRCUIT BREAKER ...........................

CIGARETTE LlGHTER ..............................

FUSE BOXES.. ..................................

OPERATOR’S SEAT ...............................

RIGIDTYPE ..................................

FORWARD-BACKWARD ADJUSTMENT ............

SEAT HEIGHT ADJUSTMENT. ...................

BACKRESTADJUSTMENT.. ....................

BUCKET TYPE SEAT (OPT) ......................

FORWARD-BACKWARD ADJUSTMENT ............

SEAT ANGLE ADJUSTMENT ....................

SEAT CUSHION ADJUSTMENT ..................

BACKREST ADJUSTMENT.. ....................

SEAT HEIGHT ADJUSTMENT. ...................

SEARS SEAT .................................

FORWARD-BACKWARD ADJUSTMENT ............

SEAT ANGLE ADJUSTMENT ....................

WEIGHT ADJUSTMENT ........................

BACKREST TILT ADJUSTMENT ..................

HEIGHT ADJUSTMENT ........................

KABSEAT ...................................

WEIGHT ADJUSTMENT ........................

HEIGHT ADJUSTMENT ........................

BACKREST ANGLE ADJUSTMENT ................

FORE AND AFT ADJUSTMENT ..................

HEADREST ADJUSTMENT ......................

RIGHT SIDE ARMREST .............................

SEAT BELT .....................................

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.........

2-29

.........

2-29 230 2-32 2-32 2-32 2-32 2-32 2-32 232 2-32 2-32 2-32 2-32 2-33 2-33 2-33 2-33 2-33 2-33 2-34 2-34 2-34 2-34 2-34 2-34 2-35 2-36

......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... ......... .........

DRAWBAR PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._...

CAB HEATER AND DEFROSTER . . . . . . . . . .

CONTROL PANEL . . . . . . . . . . . . . . . .

FAN SPEED SWITCH . . . . . . . . . . . .

FOOT / DEFROSTER SELECT LEVER AIR INTAKE SELECTOR LEVER . .

CONTROL PANEL . . . . _ . . . . . . . . . .

FAN SPEED SWITCH . . . . . . . . . .

TEMPERATURE CONTROL LEVER . .

AIR INTAKE SELECTOR LEVER . . .

METHOD OF OPERATION . . . . . .. .

CAB HEATER, DEFROSTER AND AIR CONDITIONER - IF EQUIPPED ............................

CONTROL PANEL ........................................................

FAN SPEEDSWITCH .........................................................

AIR CONDITIONER SWITCH ....................................................

TEMPERATURE CONTROLLEVER ...............................................

AIR INTAKE SELECTOR LEVER ..................................................

METHOD OF OPERATION ........................................................

PRECAUTIONS FOR USING AIR CONDITIONER .....................................

HANDLING AIR CONDITIONER IN SEASON ........................................

HANDLING AIR CONDITIONER IN OFF-SEASONS ....................................

................ ................ ................ ................ ................ ................ ................ ................ ................ ................

2-37 2-38 2-38 2-38 2-38 2-38 2-39 2-39 2-39 2-39 2-40

. .....

2-41 2-41 2-41 2-41 2-41 2-41 2-42 2-43 2-43 2-43

LOCKING FILLER CAPS .............................................................

FUELTANKFILLERCAP ..........................................................

HYDRAULlCTANKFlLLERCAP ....................................................

2-44 2-44 2-45

CHECKBEFORESTARTING ..........................................................

WALK-AROUND CHECK ..........................................................

CHECK MONITOR PANEL ........................................................

CHECK AND REFILL COOLANT ....................................................

2-46 2-46 2-46 2-47

O-8

CONTENTS CHECK AIR CLEANER SERVICE INDICATOR ...........................................

CHECK OIL LEVEL AND REFILL IN ENGINE OIL PAN ....................................

CHECKFUELLEVELAND REFILL FUEL ..............................................

CHECK AND REFILL OIL IN BRAKE OIL TANK DRAlNTHEWATERFROMTHEFUEL-WATERSiPA~’AidFi-::::::::::::::::::::::::::::::: ADDITIONAL CHECKS ...........................................................

CHECK ELECTRICAL WIRING ......................................................

OPERATING YOUR MACHINE .........................................................

BEFORE STARTING THE ENGINE ...................................................

STARTING ENGINE SPECIALSTARTING’:::::::::::::::::::::::::::::::::::::::::::::::::::::::::: COLD WEATHER STARTING.. .....................................................

COLD WEATHER WARM-UP PROCEDURE ............................................

CHECKS AFTER STARTING MOVINGMACHINEOFF...:::::::::::::::::::::::::::::::::::::::::::::::::::::: SHIFTINGGEAR ................................................................

SHIFTING BETWEEN FORWARD AND REVERSE ........................................

STEERING MACHINE ............................................................

TO STOPTHE MACHINE .........................................................

TO STOP THE ENGINE OPERATlONSAFTERSTOPPiNG’ENGl’njE::::::::::::::::::::::::::::::::::::::::::::: OPERATIONALPRECAUTIONS.. ...................................................

WORKING IN DUSTY LOCATIONS ...............................................

MAXIMUM DEPTH OF WATER ..................................................

IF WHEEL BRAKE DOES NOT WORK .............................................

PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES ..................................

LOWER THE CENTER OF GRAVITY WHEN TURNING .................................

BRAKING ON DOWNHILL SLOPES ...............................................

IF ENGINESTOPS ...........................................................

POSSIBLE WORK USING LOADER ...............................................

EXCAVATION .............................................................

LEVELING.. ..............................................................

LOADANDCARRYOPERATIONS ..............................................

LOADING ................................................................

Cross Drive Loading .......................................................

V-Shape Loading .........................................................

PARKING MACHINE .............................................................

2-47 2-48 2-48 2-49 2-49 2-50 2-50 2-51 2-51

2-52 2-53

2-53 2-55 2-56 : 2-56 2-58 2-58 2-59 2-60 2-61 2-61 2-62 2-62 2-62 2-63 2-63 2-63 2-63 2-63 2-64 2-64 2-66 2-67 2-67 2-67 2-67 2-68

ADJUSTMENT OF WORK EQUIPMENT ..................................................

ADJUSTING BOOM KICKOUT ......................................................

ADJUSTING BUCKET POSITIONER ..................................................

BUCKET LEVEL INDICATOR .......................................................

2-69 2-69 2-70 2-70

HANDLINGTIRES ..................................................................

PRECAUTIONS WHEN HANDLING TIRES .............................................

PRECAUTIONS WHEN DRIVING MACHINE ............................................

TIRE PRESSURE ...............................................................

2-71 2-71 2-71 2-71

TOWING ........................................................................

TOWING THE MACHINE ..........................................................

WHEN ENGINE CAN BE USED ..................................................

WHEN ENGINE CANNOT BE USED ..............................................

2-73 2-73 2-73 2-73

TRANSPORTATION

2-73

................................................................

COLD WEATHER OPERATION ........................................................

2-74 PREPARATIONFORLOWTEMPERATURE ............................................

2-74 FUEL AND LUBRICANTS 2-74 COOLANT ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 2-74 BAlTERY ..................................................................

2-74

o-9

CONTENTS CAUTIONS AFTER COMPLETION OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 AFTER COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75 ..........

LONG TERM STORAGE BEFORE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DURING STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AFTER STORAGE . . . . . . . . . . . . . . ..*...............................

HANDLING OF BATTERY ...............................

PRECAUTIONS FOR CHARGING BA-llERY ...............

REMOVAL AND INSTALLATION OF BAll-ERY .............

STARTING ENGINE WITH BOOSTER CABLES .............

BEFORE CONNECTING BOOSTER CABLES ...........

CONNECTING BOOSTER CABLES ..................

STARTING ENGINE .............................

DISCONNECTING BOOSTER CABLES ...............

. . . . . . . .

. . . . . . . .

TROUBLESHOOTING ................

ELECTRICAL SYSTEM ............

ENGINE .......................

CHASSIS ......................

TRANSMISSION ..............

DRIVE AXLES ................

WHEEL BRAKES .............

PARKING BRAKE .............

STEERING ..................

EQUIPMENT HYDRAULIC SYSTEM

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.. .. . .. .. .. . . .. .. . .

MAINTENANCE

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2-76 2-76 2-76 2-76 2-76 2-77 2-77 2-77

.............. .............. .............. .............. .............. .............. .............. ..............

.. ... . . . . . .. ... ...

2-75 2-75 2-75 2-75

.......... .......... .......... .......... .......... .......... .......... .......... .......... ..........

2-78 2-78 2-79 2-80 2-80 2-80 2-80 2-80 2-80 2-80

-- SECTION 3

PERIODIC MAINTENANCE

... .... ..

MAINTENANCE GUIDELINES

.

.. .. ..................

. .......

.....

.

...

. 3-2

. . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ _ . . . . . . . . . 3-2

OUTLINES OFSERVICE ..............................................................

LUBRICATION WHEN SHIPPED .....................................................

RELATING TO ENGINE ............................................................

ENGINE OIL .................................................................

COOLANT ..................................................................

DIESELFUEL.. ..............................................................

RELATING TO HYDRAULIC SYSTEM ..................................................

RELATING TO ELECTRICAL SYSTEM .................................................

RELATING TO LUBRICATION .......................................................

BLEEDING AIR ..................................................................

BLEEDING AIR FROM HYDRAULIC TANK ...........................................

BLEEDING AIR FROM THE WHEEL BRAKE HYDRAULIC CIRCUIT .........................

BLEEDING AIR FROM FUEL SYSTEM ..............................................

3-3 3-3 3-4 3-4 3-4

WEAR PARTS REPLACEMENT

3-9

PERIODICALPARTREPLACEMENT

3-5 3-5 3-5 3-6 3-7

. . . . .._...................._._........................... . . . . . . . . .._....................._....................

LUBRICANTS, FUEL AND COOLANT ............................................. ...............................................

PROPER SELECTIONTABLE ENGINE OIL .........................................................

Normal Operation ...................................................

ArcticOperation ....................................................

AXLE OIL ...........................................................

GREASE ...........................................................

o-10

3-4 3-4 3-4

3-9 .

3-10 . . 3-10 .. . .. .. .

3-11 3-11 3-11 3-12 3-12

CONTENTSDIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._.....

COOLANT . . . . . . . . . . . . ..__.............................._..................

SCHEDULED MAINTENANCE

GUIDE

3-12 3-12

........ ..... ............... .......... ........,...

3-19

OIL FILLER AND LEVEL GAUGE POSITIONS . . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . _ . . .

3-23

INITIAL 250 HOURS SERVICE ONLY ..........................................

TRANSMISSION OIL FILTER .............................................

3-25 3-25

WHENREQUIRED ......................................................

COOLANT ADDITIVE CONCENTRATION - DCA4 .............................

AIR CLEANER ELEMENT ..............................................

CHECKING .....................................................

CLEANING OR REPLACING OUTER ELEMENT ...........................

REPLACING INNER ELEMENT .......................................

CLEANING OUTER ELEMENT.. ......................................

TRANSMISSION OIL ..................................................

RADIATOR CORE ....................................................

WINDSHIELD WASHER TANKS ..........................................

DRIVEAXLEOIL .....................................................

DRIVE AXLE HOUSING BREATHERS ......................................

LUBRICATING ......................................................

BUCKET BOLT-ON CUTTING EDGE - IF EQUIPPED ..........................

BUCKET TEETH . IF EQUIPPED .........................................

BUCKET IS EQUIPPED WITH BOLT-ON TEETH ...........................

BUCKET IS EQUIPPED WITH WELDED ON OR REPLACEABLE TIP TEETH PARKING BRAKE ....................................................

INSPECTION ....................................................

ADJUSTMENT ...................................................

LENGTH OFLEVER ..................................................

AIR CONDITIONER CONDENSER - IF EQUIPPED ............................

AIR CONDITIONER REFRIGERANT CHARGE - IF EQUIPPED ....................

STEERING .........................................................

HYDRAULIC SYSTEM .................................................

SERVICE METER ....................................................

...

3-25 3-25 3-25 3-25 3-26 3-26 3-27 3-28 3-28 3-29 3-29 3-30 3-31 3-33 3-33 3-33 3-34 3-35 3-35 3-35 3-36 3-36 3-37 3-38 3-38 3-38

......

CHECK BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 EVERY50 HOURSSERVICE ...............................................

FUELTANK ........................................................

TIRES ............................................................

3-39 3-39 3-39

EVERY100 HOURS SERVICE .........................................................

HYDRAULICTANK ..............................................................

LUBRICATING .................................................................

CAB AIR FILTER -IF EQUIPPED ....................................................

AIR CONDITIONER FILTER - IF EQUIPPED ............................................

3-39 3-39 3-40 3-41 3-41

EVERY 250 HOURS SERVICE . ........... . .. . . ....

LUBRICATING WHEEL HUB Bdifi ::::::::::::::: :: :::::::::::::::: ENGINE OIL PAN AND FILTER ... .. .... ..... .. .....

BATTERY ELECTROLYTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INTAKESYSTEM . . . . . . . . .._.....................

AIR CONDITIONER COMPRESSOR DRIVE BELT - IF EQUIPPED EVERY500 HOURS LUBRICATING FUELFILTERS GENERAL

SERVICE ......................................................... ................................................................. ................................................................. .................................................................

.. . . .... .. ... .... .. .

.......... .......... .......... .......... .......... .......... ..........

3-42 3-42 3-44 3-44 3-45 3-46 3-46 3-47 3-47 3-48 3-48

O-l1

CONTENTS REPLACEMENT .............................................................

TRANSMISSION OIL FILTER .......................................................

ANTIFREEZE CONCENTRATION ....................................................

AIR DRYER-IFEQUIPPED ........................................................

3-48 3-50 3-50 3-50

EVERY1000 HOURSSERVICE ........................................................

LUBRICATING .................................................................

TRANSMISSION CASE BREATHER ..................................................

TRANSMISSION OIL AND STRAINER ................................................

ENGINEVALVES ...............................................................

DRIVE BELT.. .................................................................

DRIVE BELT, TENSIONER BEARING AND FAN HUB .....................................

EVERY 2000 HOURS SERVICE . . . .

DRIVE AXLES . . . . . . . . . . . . . .

HYDRAULIC TANK BREATHER .

HYDRAULIC TANK AND FILTER BRAKE DISC VIBRATION Dblkk :::: :::: COOLING SYSTEM . . . . . . . .

AIR CONDITIONER FILTER . .

SPECIFICATIONS

. . . .

. . . .

:: .. ..

.. ...... ... ..... .. .... .. ........ ........

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . .

. . . . . . . ..

. . . . . .

. . . . . . . ..

. . . . . . . .

. . . . . . . .

. . . . . .

. . . . . .

. . . . . . . .

. . . . . . . .

. . . . .

361 3-51 3-53 3-53 3-54 3-57 3-57

. . . . .

... ... ... . .

3-58 3-58 3-60 3-61 3-62 3-62 3-63 3-65

-- SECTION 4

GENERALSPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

STANDARD TIGHTENING TORQUES .....................................................

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS .................................

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS .......................................

TIGHTENING TORQUE FOR NUTS OF FLARED FllTlNGS ..................................

UNITCONVERSIONS ................................................................

AREA ........................................................................

DENSITY (Mass Density) ..........................................................

FORCE FORCEPERiiNGiH:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: HEAT ........................................................................

LENGTH .....................................................................

MASS(WEIGHT) ...............................................................

POWER ......................................................................

PRESSURE TEMPERATURi’:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: TEMPERATURE INTERVAL OR TOLERANCE ...........................................

VOLUME .....................................................................

TORQUE .....................................................................

VELOCITY ....................................................................

o-12

.

................ ................ ................ ................ ................ ................ ................ ................

4-7 4-7 4-7 4-8 4-9 4-10 4-10 4-l 1 4-l 1 4-11 4-12 4-12 4-13 4-13 4-l 3 4-14 4-14 4-15 4-15

CONTENTS

MEMORANDUM

O-l 3

CONTENTS

MEMORANDUM

o-1 4

1

SECTION SAFETY PRECAUTIONS

A

WARNING ! REFER TO AND READ ALL SAFETY PRECAUTIONS

IN SECTION

1.

l-l

SAFETY PRECAUTIONS AVOID ACCIDENTS WORK SAFETY -- FOLLOW THESE RULES A CAREFUL OPERATOR IS THE BEST INSURANCE AGAINST AN ACCIDENT

A

This symbol is used throughout this manual to call your attention to instructions concerning personal safety. Observe and follow these instructions.

Be certain anyone operating or servicing this machine is aware of these rules. Failure to follow these rules may result in injury or death.

GENERAL

PRECAUTIONS

PERSONNEL PRECAUTIONS Operating and servicing this machine can be hazardous if performed improperly. Personnel must have the necessary skills, information and equipment and use safe and proper procedures. Study the Operation and Maintenance Manual before operating or servicing this machine. Consult your Distributor for information and service.

Only trained and authorized personnel should allowed to operate and service this machine.

be

Read all warning product graphics before starting, operating, maintaining or repairing this machine.

DO NOT wear jewelry or loose fitting or hanging clothing because they could catch on moving parts and cause injury or death. Wear proper safety equipment, such as a hard hat, rough-soled work shoes or safety shoes, ear protectors, reflective vests, respirators, safety glasses, goggles and heavy gloves.

Consult your employer for specific requirements.

DO NOT jump on or off the machine. Keep two hands and one foot, or two feet and one hand, in contact with the steps and handholds at all times. Place objects on machine from ground level before climbing on. Always face the machine when climbing on or off to reduce the chances of slipping and injury.

Think before you act. Careful operators and service personnel are the best insurance against accidents.

When there is a leader, fix standard signals and always follow these signals when operating.

Learn the prohibitions, cautions and rules about work procedures in each work site.

Do not rush. Hurrying can lead to accidents. Haste, carelessness and lack of training are the primary causes of equipment-related injuries.

MACHINE PRECAUTIONS Carefully evaluate your application’s particular safety needs. Each machine application can have unique requirements. You may need such attachments as: rear windshield wipers, windshield washers, heater, defroster fan, warning lights, air conditioning, ROPS, mirrors, backup alarm, fire extinguisher, spark arrestor, fire suppression system, cab screens, sound suppression, rotating beacon, additional lights, antivandalism attachments, guards, tow hook, Lexann windows, water glycol, communication radios, ground driven steering, turn signals, and slow moving vehicle sign. Consult your Distributor for information.

Be sure the machine has the correct required by local rules and regulations.

It is recommended that the machine be equipped with a fully charged fire extinguisher with an Underwriter’s Laboratory (UL) rating of 2A:lOB:C (or higher).

Personnel should be instructed in proper usage.

Recharge immediately after use.

If the machine will be used for tree removal or site clearing, install approved operator guards per S.A.E. or OSHA requirements. Consult your Distributor for information.

equipment

A rollover protective structure (ROPS) with a seat belt is required by OSHA in almost all applications. DO

1-2

NOT operate this machine without a ROPS.

If the machine will be working under conditions of flying combustible material, install screens and guards to reduce the chance of fire.

SAFETY PRECAUTIONS If the machine is equipped with a suction fan (or a reversible fan in the suction position), check the engine exhaust system periodically for leaks. Exhaust gases are dangerous to the operator. On machines equipped with a cab, keep a vent open to outside air.

Keep shields and guard in place for your protection.

Be sure to replace them after servicing the machine.

A first-aid kit should be available in case of an injury.

When transporting the machine, use caution when loading and unloading it. Load and unload the machine in a level area which fully supports the machine and transport vehicle. Block the transport vehicle so it cannot move. Use loading ramps of adequate strength, low angle and proper height. Keep the trailer bed and the machine’s tires clean of clay, oil and other slippery materials. Lock the machine’s front and rear frames together with the frame locking bar and pins. Apply the machine’s parking brake.

Block the tires and securely tie down the machine and the machine tires, to the trailer bed.

OPERATION BEFORE STARTING Before entering the operator’s compartment, walk completely around the machine and clear the area of personnel and obstructions.

Perform a visual check of the machine before starting the engine. Look for such things as missing protective devices, leaks, improper fluid levels, trash buildup and loose, damaged or missing parts. DO NOT start the engine until any unsafe conditions are corrected.

Before operating the machine, check that the frame locking bar and pins are in the storage position on the rear frame. A broken or lost frame locking bar or pins should be replaced immediately so that this device is always available for use.

Be sure all filler caps, dipsticks, plugs, latches, service doors, etc., are secure before starting.

BE SURE the operator’s compartment, mounting steps and handholds are free of oil, grease, snow, ice, mud and foreign objects to reduce the possibility of slipping and injury. Repair any damaged steps or handholds. Remove or secure all maintenance and

personal items which might interfere with the operator or jam the controls.

Do not use the machine’s controls or hoses as handholds when climbing on or off the machine.

Controls and hoses can move and do not provide solid support. Movement of the controls may cause unexpected machine movement and injury.

Understand engine.

all control functions

before starting the

Know the alternate exit routes from the operator’s compartment for use in an emergency.

If the machine is equipped with a cab, the right hand side door of the cab serves as an emergency exit.

Use only if the left hand side door is blocked.

The operator must be alert, physically fit and free from the influences of alcohol, drugs and medications that might affect his eyesight, hearing or reactions.

Safety must always be the operator’s most important concern. He must refuse to operate when he knows it is unsafe and consult his supervisor when safety is in doubt.

1-3

SAFETY PRECAUTIONS

START-UP Never start the engine indoors unless proper exhaust ventilation is provided to remove deadly exhaust gases. Once the engine is running, move the machine outdoors as soon as possible. Exhaust gases are hazardous and can cause unconsciousness and death.

Sit in the operator’s seat before operating any controls. Keep hands and footwear free of grease,

Use of the seat belt with the ROPS is strongly recommended. In the event of a rollover, stay with the machine. Experience has shown this will reduce the chance and seriousness of injury.

Before moving the machine, check the brakes, steering, attachment controls and safety devices. DO NOT operate the machine until any unsafe conditions have been corrected.

water and mud to insure positive control movement.

Before starting the engine, or when machine is standing with the engine running: place the transmission directional lever in neutral (N), apply the parking brake and lower any raised equipment.

DO NOT SMOKE when using the ether start. Do not use the ether start when the air temperature is above freezing. Follow the correct method for starting the engine. Refer to “STARTING ENGINE” in Section 2.

Before driving the machine, adjust the seat and fasten the seat belt. Adjust the seat for maximum comfort and control of the machine. Adjust the seat belt to fii snugly and low around the hips to lessen the chance and severity of injury in the event of an accident.

Never wear the seat belt across the abdomen.

GENERAL

OPERATING

Stay alert and aware of what you are doing. Use common sense. Do not operate when fatigued or ill.

Know your machine and its capabilities. Use the machine only for its intended purposes. For your safety, read the Operation and Maintenance Manual carefully and follow all instructions and precautions.

Provide proper ventilation when operating in a closed area to minimize the danger of exhaust gases.

Exhaust gases are hazardous and can cause unconsciousness and death.

Maintain clear vision of all work and travel areas. Keep windows and mirrors clean and repaired.

Look in the intended travel direction to be sure personnel and allied equipment do not interfere with the machine’s work pattern. Do not operate if exposed personnel enter the immediate work area.

Turn on the machine’s lights at night and times of poor visibility to see and be seen.

DO NOT adjust the seat while the machine is moving

1-4

Before moving the machine, sound the horn to warn nearby personnel.

Release the parking brake before moving the machine. The brake could burn or be damaged if the machine is driven with it applied.

Turn off the defroster fan before adjusting it to avoid injury.

NEVER HAUL PASSENGERS. Only the operator should be on the machine when it is moving.

Use caution and follow the manufacturer’s instructions when using external heaters to warm the power train in cold weather.

PRECAUTIONS because a loss of control may result. Stop the machine, apply the parking brake and then adjust the seat.

Keep head, limbs and body inside the operator’s compartment at all times because of the chance of being injured by hazards outside the operator’s compartment.

NEVER allow anyone near the center articulation pivot. If the machine turned, they could be crushed.

NEVER allow anyone to stand on the ladder when the bucket is raised or the machine is moving or turning to prevent injury from falling, crushing or falling material.

NEVER get on or off the machine while it is moving because serious injury or death could result.

After starting and while operating, observe instruments and warning lights frequently. Investigate any unusual indications or noises in the machine.

SAFETY PRECAUTIONS If the engine has a tendency to stall, investigate immediately. Do not operate the machine until the cause has been corrected.

If noise exposure exceeds 90 dBA for eight hours, wear ear protective equipment.

DRIVING THE MACHINE Carry the bucket low for maximum stability when traveling.

. . .. vrsrbrlrty and

Before operating in areas with overhead obstructions, carefully check overhead clearance. Obstructions, such as guy wires, power lines, tree branches, bridges and building doors could cause a rollover accident.

Drive slowly enough to insure complete control. Slow down when traveling in congested areas or on mud, ice or other slippery surfaces. Keep a safe distance away from other vehicles, according to the load and ground conditions.

Avoid crossing obstacles, such as ridges, curbs, logs and rocks. If you cannot avoid them, reduce speed and cross at an angle. Ease up to the breakover point, pass the balance point slowly and ease down on the other side.

Cross ditches and gullies slowly and at an angle after checking that the ground will safely support the machine.

Avoid sidehill travel whenever possible. Drive straight up and down the hill. If the machine starts slipping sideways, turn downhill immediately.

When traveling on hills with a loaded bucket, travel forward up the hill and in reverse down the hill.

Stop, look and listen before entering a highway. Stay on the right side of the road. Slow down and signal when turning off.

When roading the machine, engage the hydraulic control lever lock to guard against accidental actuation of the levers. Personal injury could result if the bucket catches on a ledge in the road.

Never shift the transmission into neutral (N) when traveling downhill. The machine could go out of control or the power train could be damaged when the transmission is shifted into gear again.

Do not overspeed the engine. Excessive speeds can be hazardous and harmful to the power train. Select the proper gear before starting downhill. Control speed with the brakes.

Never use the bucket as a brake except in an emergency. It might catch on the ground and result in personal injury.

If the main steering light comes on, IMMEDIATELY stop the machine in a safe place. Shut off the engine and apply the parking brake. Correct the cause before operating again.

If the brake system warning light or buzzer comes on during operation, IMMEDIATELY stop the machine in a safe place. Apply the parking brake. Correct the cause before operating again.

Know the traffic flow pattern of the job site. Obey flagmen, signs and signals.

Give the right-of-way to loaded machines. On narrow or hilly roads, loaded machines should stay next to the high wall.

Keep the machine as close to the side of the road as safely as possible to leave room for oncoming and passing vehicles.

Pass other vehicles only when the road is clear and the machine has enough distance and reserve power to pass.

Do not use the transmission disconnect brake pedal when traveling fast or going downhill because this shifts the transmission into neutral. Loss of control or damage to the power train could result when the pedal is released and the transmission is re-engaged.

1-5

SAFETY PRECAUTIONS

OPERATING THE ATTACHMENTS Check the work area for hazardous conditions. Be alert for soft ground conditions, especially when working on slopes, near dropoffs or excavations or on fill material, which could lead to sudden tipping of the machine.

Keep the work area free from obstructions smooth, as possible.

DO NOT swing a load over the heads of other workers or a truck cab.

If the loader begins to tip over because of an overload, IMMEDIATELY lower the bucket to regain stability.

and as

Know the locations of underground cables, water mains, gas lines, etc. A broken gas line or electrical cable could cause personal injury or death.

Avoid operating too close to an overhang, deep ditch or excavation because the machine’s weight and vibration may cause the edge to collapse and result in personal injury. If this cannot be avoided, use extra caution and face the machine toward the edge while operating.

Avoid undercutting high banks because the bank may cave in. Ramp up and remove the top layers first.

Trucks should be loaded from the driver’s side whenever possible. When the truck is being loaded, be sure the driver either stays in the cab (on cabprotected trucks) or away from the truck and loader.

When loading trucks, be careful not to hit the truck with the loader or its bucket.

There in no substitute for good judgment when working on a slope. Slope operation should be limited by ground and traction conditions, the load being carried and the speed of the machine.

NEVER operate sideways on a steep slope because a rollover and serious injury could result.

Using the loader to carry large objects which do not fit into the bucket is NOT recommended. Handling large objects can be extremely dangerous because the objects may roll or slide down the lift arms onto the operator. NEVER lift large objects higher than the operator unless the machine has a device which prevents the objects from falling back onto the operator.

When pushing over trees, the machine must have approved operator protection. Back away immediately when the tree starts to fall. Use extreme care when pushing over trees with dead branches which may fall.

To reduce the chance of machine upset, never allow the machine to climb up the root structure.

Use extra caution when moving with the bucket raised to minimize the chance of machine upset.

PULLING/TOWING For your safety, never push machine farther than absolutely onto a truck.

or tow a disabled necessary to load it

When using a chain or cable, be sure it is strong enough for the expected load and properly secured to the drawbar pin.

Hitch only to the drawbar pin. Machine result if pulling from the wrong location.

upset can

When pulling, position the machine so that the chain or cable aligns with the long axis of the machine.

Inspect chains and cable for flaws before using. Avoid

1-6

kinking. Do not pull with a kinked chain or cable because the high stresses could cause a failure in the kinked area. Wear heavy gloves when handling chain or cable.

When pulling with a chain or cable, take up the slack slowly to avoid jerking. A chain or cable which fails under load can whip and cause serious injury. STAND CLEAR. DO NOT PULL OR TOW UNLESS THE OPERATOR’S COMPARTMENT IS GUARDED AGAINST OR OUT OF REACH OF A WHIPPING CHAIN OR CABLE.

SAFETY PRECAUTIONS

SHUTDOWN Never leave the machine with the engine running or the bucket raised. When parking the machine, shut off the engine, lower the bucket to the ground, place the transmission directional lever in neutral (N), apply the parking brake, turn off the electrical starting switch and remove the key.

Raised liti arms will drop when the control lever is moved to “LOWER” or “FLOAT” even with the engine off. ALWAYS lower the lift arms when parking the machine.

If the machine is equipped with a multi-purpose bucket, close the clam before dismounting.

Park the machine in a non-traffic area. If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and warning signals. Also provide advance warning signals in the traffic lane for approaching traffic.

Avoid parking on a slope because unexpected machine movement may occur. If necessary to park on a slope, park at right angle to the slope and block the tires.

Always lock the machine, including any anti-vandalism attachments, when leaving it unattended.

MAINTENANCE GENERAL

MACHINE

Constantly be aware of dangers involved in working on the machine and take proper precautions. It is not possible to anticipate all conceivable ways or conditions under which this machine may be serviced or to provide precautions for all the possible hazards that may result. Safety is always the most important rule. Standard and accepted safety precautions and equipment should be used.

Do not attempt repairs you do not understand.

Consult your Distributor for information and service.

NEVER run the engine when cleaning or lubricating the machine because serious injury could result from contacting moving parts.

Before servicing the machine, BE SURE the engine is off, the bucket is lowered, the transmission directional lever is in neutral (N), the parking brake is applied and the ,electrical starting switch is off and the key is removed. Tag the machine.

Before working on the engine or electrical system, disconnect the negative (ground) battery cable. Tag the cable and controls to warn against starting.

Before working under the machine, block the tires to prevent machine movement.

ALWAYS lock the front and rear frames together with the safety bar and pins before working near the center of the machine. If the frames move, serious injury could result.

PRECAUTIONS NEVER stand near the bucket or the tires while the engine is running.

During servicing, DO NOT allow anyone in the operator’s compartment who is not trained and assisting in the servicing.

When it is necessary to make any checks or adjustments with the engine running, use two people.

A trained operator must be at the controls to safeguard the mechanic making the checks or adjustments. BE SURE the transmission directional lever is in neutral (N), the parking brake is applied and the front and rear frames are locked together.

Be sure the engine hood or access door(s) is secure in the open position during service work in the engine compartment. Unexpected closing could cause injury.

NEVER remove any guards or shields with the engine running because of the danger of contacting rotating parts.

When service requires access to areas that cannot be reached from the ground or a service platform on the machine, use a ladder or platform of appropriate capacity.

Use only approved parts for repairs and maintenance.

Failure to do so could compromise personal safety, machine performance and reliability.

1-7

SAFETY PRECAUTIONS This machine is assembled using high strength fasteners. Replacement fasteners must be of the same size and strength as the originals.

DO NOT SUBSTITUTE. Refer to the Parts Book for this machine. Tighten fasteners to the proper torque. Refer to Section 4.

Replace any missing or defaced product graphics.

When parts which have product graphics on them are replaced, be sure to install new product graphics.

GENERAL

WORK

Keep work area clean and dry. Remove water and oil spills immediately to reduce the chance of slipping and injury.

Do not pile up oily or greasy rags; they are a fire hazard. Store them in an approved, closed metal container.

Use a non-toxic, non-flammable commercial solvent for cleaning parts, unless otherwise specified.

Avoid use of gasoline, diesel fuel, kerosene or other flammable solvents for cleaning parts. NEVER place these solvents in an open drain.

Corrosion inhibitors are volatile and flammable. Use them only in a well ventilated area. Keep flames and sparks away. Do not smoke. Store container in a cool, well ventilated place.

Avoid prolonged exposure to volatile corrosion inhibitors because eye and skin irriiation may occur.

Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact, remove sealant or solvent promptly by washing with soap and water. Follow the manufacturer’s advice whenever cleaning agents or other chemicals are used.

Wear eye protection when using air or water under pressure to clean parts. Limit air pressure to 2.1 kg/cm2 (30 psi / 200 kPa) and water pressure to 2.8 kg/cm2 (40 psi / 275 kPa).

New product graphics are available from your Distributor. For the proper position of the product graphic, refer to “SAFETY PRODUCT GRAPHICS AND LOCATIONS”.

NEVER adjust relief valves higher than the specified pressure because this may damage the machine and lead to an injury. When checking pressures, use the correct gauge for the expected pressure. Consult your Distributor for information and service.

PRECAUTIONS When welding, wear proper protective equipment, such as a helmet, dark safety glasses, protective clothing, gloves and safety shoes. DO NOT LOOK AT THE ARC WITHOUT PROPER EYE PROTECTION. If necessary to do welding on the machine, attach the ground cable close to the weld area. Do not attach the ground cable where the current can flow through bearings or mounting pads because this will damage the parts.

Use extra caution when jacking up the machine.

Jacking up the machine can be hazardous if performed improperly. Use jacking equipment of sufficient capacity. Be sure the jacking points are strong enough to support the machine. Be sure the jack is stable and well supported. Before jacking up the machine, block the tires which will not be lifted.

Lock the front and rear frames together with the locking bar and pins. If the rear tires are being lifted, block the rear axle to prevent it from pivoting unexpectedly.

DO NOT run the engine with the machine on jacks. For your safety, transfer the weight of the machine to approved blocks, before servicing the machine.

Use the proper tool for the job. Be sure all tools are in good condition. Do not use tools which are worn, bent or have mushroomed heads because they can lead to injury.

Never align holes with fingers or hands. Use the proper aligning tool to avoid injury.

Remove sharp edges and burrs from reworked parts.

When cutting, grinding, pounding, prying or whenever material could fly or fall, wear proper protective equipment such as goggles, hard hat, safety shoes and heavy gloves. Many of the machine’s parts are hardened and can chip.

Wear hand and eye protection fluids.

1-8

when draining

hot

Do not carry loose objects in pockets because they might catch on the machine and result in a fall or injury.

Use only properly grounded auxiliary power sources for chargers, heaters, electrical drills and similar equipment to reduce the chance of electrical shock.

SAFETY PRECAUTIONS Lii and handle all heavy parts with lifting devices of adequate capacity. Secure parts with proper slings and hooks. Use lifting eyes provided. Warn nearby personnel to stand clear.

DO NOT use the bucket to I’m personnel or as a work platform. Mechanical failure or human error could cause unexpected movement of the attachment and serious injury or death.

ATTACHMENTS For your protection, use EXTRA caution when adjusting the loader’s bucket positioner or boom positioner. Use two trained people and guard against accidental movement of the machine or loader linkage.

For your protection, keep head, body, hands and fingers away from the bucket and linkage when they are in a raised position, unless they are securely blocked.

When replacing cutting edges and teeth, securely block the bucket for your protection.

To install and remove bucket teeth, use a nonferrous hammer. It is hazardous to hammer on the teeth.

Wear safety glasses with side shields or goggles to reduce chances of injury.

BRAKES Block the tires to prevent machine movement before servicing the brakes.

the machine on level ground and block the tires to prevent it from moving.

Test the parking brake periodically. If the parking brake does not hold the machine, correct the cause as soon as possible. Until the cause is corrected, park

When testing the parking brake, be sure the area near the machine is clear of personnel and obstructions because the machine may move during the test.

CAB/ROPS Do not attempt to repair a rollover protective structure (ROPS) after an accident. The ROPS is designed to bend during a rollover to protect the operator from sudden impact loads. Repaired structures do not provide the original strength and protection. O.S.H.A. regulations prohibit repair to damaged ROPS. Contact your Distributorfor information on ROPS replacement.

Do not operate the machine again until the ROPS has been replaced.

Periodically inspect the ROPS for fatigue cracks.

Cracks indicate a weakened structure which should be replaced for your protection.

Do not use bleach, dye or solvents on the seat belt because this may weaken the webbing and result in personal injury. Clean the seat belt with warm water and a mild detergent. Replace belts with worn, frayed, torn, faded, stiff or rotted webbing.

Do not cut, grind, weld or drill holes in the ROPS because this could weaken the structure or affect its energy absorption capability.

COOLING Hot, scalding coolant can spray out if the radiator cap is removed suddenly. Relieve system pressure by slowly turning cap to the first notch or lifting the safety lever (ii equipped). Remove the cap ONLY after the pressure is relieved.

Use extreme caution when adding coolant to a hot radiator to avoid being burned. Wear gloves and goggles and keep face away from the filler neck.

1-9

SAFETY PRECAUTIONS ELECTRICAL Batteries give off a highly flammable gas. DO NOT SMOKE or allow sparks or open flame near the batteries because a fire or explosion could result.

BE SURE the electrical starting switch is off when connecting or disconnecting batteries to minimize the chance of sparks and explosion.

DO NOT allow metal tools or a jumper cable clamp to contact the positive battery terminal and any other metal on the machine. The resulting sparks could cause an explosion.

When using a booster battery and jumper cables, connect the negative (ground) cable to the machine frame, AWAY FROM THE BATTERY. ALWAYS connect the ground cable last and disconnect it first to avoid sparks near the battery. A spark could cause a battery explosion and injury.

NEVER check the battery charge by placing a metal object across the terminals. The sparks could cause a battery explosion. Use a voltmeter or hydrometer to measure charge.

Battery acid causes severe burns. Avoid contact with eyes, skin or clothing. Wear goggles, rubber gloves and apron. If skin contact occurs, flush with water. If eye contact occurs, flush with water for 15 minutes and get prompt medical attention.

The engine can be started with the transmission in gear if the neutral start switch is bypassed. Do not connect across the terminals on the starter motor.

Attach booster batteries as directed in this manual.

DO NOT charge batteries in a closed area. Provide proper ventilation to guard against explosion of an accumulation of the gas given off in the charging process.

ENGINE Do not go into the engine compartment without securing the engine access panel door. Accidental closure of the door could cause injury.

C.

DO NOT SMOKE when fluid.

d.

DO NOT store fluid containers in the operator’s compartment or in direct sunlight.

Store containers in a cool, well ventilated place.

e.

Keep the fluid containers children.

Do not rework or modify the engine flywheel because this could weaken it and lead to a failure.

Keep the engine exhaust manifold(s) and exhaust system clear of combustible material to reduce the chance of fire.

using ether starting

out of the reach of

f. Do not breathe the hazardous ether vapor.

Ether starting fluid is highly flammable. Follow the precautions on the container. An explosion can result if sparks or flame contact the ether in the container or if the container is stored where the temperature exceeds the temperature listed on the container.

Observe the following precautions: a.

b.

I-10

Follow the correct method for starting the engine. Refer to “STARTING ENGINE” in Section 2.

Do not use the ether start when the air temperature is above freezing.

g.

Do not let ether contact your skin because it can cause frostbite.

h.

NEVER puncture the fluid container or put it into a fire. Dispose of empty containers properly.

i. For your safety, remove the ether container when welding, grinding or using a torch on the machine.

SAFETY PRECAUTIONS

FUEL SYSTEM NEVER remove the fuel filler cap or fill the fuel tank while the engine is running or when the machine is indoors. The fumes are hazardous and a spark or flame could cause a fire or explosion.

DO NOT SMOKE while filling the fuel tank or servicing the fuel system because a fire or explosion could result.

When filling the fuel tank, place the fuel nozzle against the side of the filler neck to reduce the chances of static electricity sparks.

NEVER mix gasoline, gasohol or alcohol with diesel fuel. This creates a fire or explosion hazard which could result in personal injury or death.

HYDRAULICS For your safety, lower the bucket before servicing the machine. Be sure no one is standing near the bucket when it is being lowered.

Loosen the filler cap slowly to relieve the pressure before disassembly of any hydraulic system components. DO NOT OVERFILL.

NEVER work under a raised bucket without blocking.

DO NOT use hands to search for hydraulic leaks.

Hydraulic oil escaping under pressure from a very small hole can be almost invisible, yet have sufficient force to penetrate the skin. Use a piece of cardboard or wood to search for suspected leaks. If injured by escaping oil, see a doctor immediately because of the possibility of serious infection or reaction to the oil.

proper

Before working on the hydraulic system, be sure the system pressure is relieved by moving the control levers in all directions with the engine off.

This machine has a pressurized hydraulic reservoir.

TIRES Tire and rim repairs MUST be done by specially trained people using special safety tools. An improperly repaired tire or rim can separate suddenly and cause serious injury.

NEVER inflate a flat tire without inspecting the tire, rim and wheel for damage. Be sure all components are properlyassembfed. Unmounted tires being inflated or

AND RIMS deflated should be placed in a tire safety cage. Inflate the tire to 0.3 kg/cm2 (5 psi / 35 kPa) and check that all components are properly seated. NEVER stand directly in front of a tire and rim assembly while inflating. Use a clip-on chuck with a hose long enough to allow the person inflating the tire to stand to the side. Serious injury could result if the tire and rim were to separate.

TURBOCHARGER In certain types of engine service, the turbocharger air inlet hose must be removed so other parts are accessible for service or repairs. When the air inlet hose is removed, THE TURBOCHARGER IMPELLER IS EXPOSED AND CAN CAUSE SERIOUS PERSONAL INJURY AND/OR ENGINE DAMAGE. Engine

operation creates a vacuum in the compressor strong enough to suck objects into the impeller. It imperative to install a safetv shield on the turbocharaer inlet ooenina whenever air inlet hoses are removed. Failure to follow this precaution could result in serious injury.

l-11

SAFETY PRECAUTIONS VITON The maximum operating temperature of our hydraulic system is 220°F (105°C). Under abnormal conditions, the operating temperature can reach 266°F (129°C).

The VITON seal is made from fluorine rubber material and is rated to operate up to 450” F (232” C).

A

SEALS Make inquires to determine the suspect material composition.

If the material is a Flouro-Elastomer, (Viton, Flourel or Tecmoflon), it should be considered dangerous.

WARNING! When VITON fluorine rubber material is subjected to an open flame or temperatures exceeding 599°F (315°C) it will produce highly corrosive “Hydra Flouric Acid”. The resulting contamination can have extremely harmful conseauences to human tissue. It is almost impossible to remove after contact.

If Flouro-Elastomer parts have been used, the affected area must be decontaminated before undertaking further work.

The following procedures are recommended to be utilized when it is necessary to inspect or repair any equipment that has been subjected to high temperatures from causes such as fire, extreme operational overheat, etc.

Disposable heavy duty gloves made of Neoprene must be worn throughout the decontamination process. Decontaminate the affected area by washing thoroughly with limewater, a Calcium Hydroxide solution.

1.

Visually inspect for any gasket, seals or O-rings which have suffered from heat; they will appear black and sticky.

Any cloths and residue as well as the gloves worn during decontamination must be safety discard after use.

2.

If this is confirmed,

1-12

DO NOT TOUCH!

However, if the material is found to be “Natural Rubber” or “Nitrile” it can be considered nonhazardous.

NOTE: Burning of discarded items is not recommended except in an approved incineration process where the dangerous products are treated by Alkaline scrubbing.

SAFETY PRECAUTIONS SAFETY PRODUCT

GRAPHICS

//

l3 11

AND LOCATIONS

\ 7

\

1

L02AD13i

1-13

SAFETY PRECAUTIONS

LOZAD133

1-14

SAFETY PRECAUTIONS

VIEW

VIEW

A

B

8

VIEW VIEW

F

G

SAFETY PRECAUTIONS Always keep these product graphics clean. If they are missing or damaged, replace them with a new product graphic. Replacement product graphics can be ordered from your distributor.

In addition to safety product graphics, the machine has instructional and identification product graphics,

1.

which should be treated described above.

Safety product graphics may be available in languages other than English. To find out more information about foreign language product graphics, contact your distributor.

Caution for ladder.

PN

1-16

161 177

H5

in the same manner as

LOZADlOl

SAFETY PRECAUTIONS 2.

Caution for rollover.

L02AD102

l-17

SAFETY PRECAUTIONS 3.

Caution for pressurized cooling system.

PN

4.

204

166

Cl

LOZAD099

Caution for hydraulic reservoir.

PN

1-18

2754

473 R3

L02AD103

v/

.

IH SIDF BAllFRlFS

IWITH DRAINFI) A4liERlFSI

lFRMlNAl

S IO FAT.11 I-llllF

(:flNNLI:I rllFPllSlllVF

RH SIDE BAnERIES

416-93-11440m

HlClE (ASSIST CAR)

lWHEN CONNECTING THE BAllERY CABLES, BE SURETO CONNECTTHE GROUND SIDE (SHIELOED WITH A BLACKTUBE I LAST.

0 TO USE THE BATTERIES OF ANOTHERVEHICLE (EQUIPPED WITH 24-V BATlERIES) TO START THE ENGINE, CONNECT THE BOOSTER CABLES INTHE ORDER SHOWN ABOVE. l AFTER STARTING THE ENGINE, DISCONNECT THE BOOSTER CABLES IN THE REVERSE ORDER INWHICH THEY WERE CONNECTED. 0 FDR DETAILS. SEE OPERATION AND MAINTENANCE MANUAL.

lHEFRAME

CONNECT TO

WHEN THE BAllERIES ARE DRAINED

~WHENREMOVlNGTHEBATTERIES,RETlGHTENlNG

THEBATTERY TERMINALS, OR MAKING REPAIRS ON THE ELECTAICALSYSTEM, BE SURE TO DISCONNECT THE GROUND SlDETERMlNALlSHlELDED WITHA BLACKTUBE) FIRST.

BAlTERlES

RH SIDE BA?lERlES

SAFETY PRECAUTIONS 6.

Caution for battery charging.

LOZAD105

7.

Caution for transmission

oil level.

1

IMPORTANT

Check with engine at idle and transmission in neutral. Oil temperature 150°F. to 200°F.. Use recommended oil.

Ul-93.A1120

LOZAD106

8.

Warning for brake oil.

USE ONLY ENGINE OIL ,419-93-10

LOZAD107

l-20

SAFETY PRECAUTIONS 9.

Caution for operator instructions.

LOZAD108

1-21

SAFETY PRECAUTIONS 10. Warning for operator and instructions.

LOZAD109

l-22

SAFETY PRECAUTIONS 11. Danger for frame locking bar.

Install locking bar (front frame to rear frame) in the following cases.

1. When performing inspection or maintenance in center hinge area.

2. Transporting 3. Hoisting

vehicle.

or lifting

vehicle.

Locking bar must be disconnected prior to normal operation.

DO NOT DEFACE OR REMOVE THIS DECAL 421-93-A1140

12. Caution for engine fan and fan belt.

LOZADlll

l-23

SAFETY PRECAUTIONS 13. Danger for no clearance between frames.

FRONT AND REAR FRAMES CAN

PIVOT

RAPIDLY

- STAY CLEAR OF TIRES AND CENTER HINGE AREA WHILE ENGINE IS RUNNING. DO NOT DEFACE OR REMOVE THIS DECAL 423-93-11420

PN 1170

l-24

724

C2

L02ADlOO

_

SAFETY PRECAUTIONS BEFORE

CARRYING

OUT MAINTENANCE

WARNING TAG 0

If others start the engine or operate the controls while you are performing service or lubrication, you could suffer serious injury or death.

l

ALWAYS attach the WARNING TAG to the control levers in the operator’s cab to alert others that you are working on the machine. Attach additional warning tags around the machine, as necessary.

l

These tags are available from your distributor.

(Part No. 09963-03000).

L02AD185

l-25

SAFETY PRECAUTIONS

MEMORANDUM

l-26

SECTION

2

OPERATION

A

WARNING SAFETY

! REFER

TO

PRECAUTIONS

AND IN

READ SECTION

ALL 1.

2-1

OPERATION GENERAL VIEW

7

6

5

LllADOl

Wheel Loader With Cab and ROPS Canopy 1.

2.

3.

4.

2-2

Bucket Lii arm Head lamp Turn signal lamp

5.

6.

7.

Rear tire and wheel Safety bar Front tire and wheel

8.

Lift cylinder 9.

Dump cylinder 10. Tilt lever

OPERATION INSTRUMENTS AND CONTROLS MONITOR PANEL

LllADOlZ

This monitor panel consists of monitor lamp groups (A, B and C), meter group (D) and warning lamp (E).

A.

If there is any abnormality, monitor lamp will flash. *

B.

can operate, but it should be repaired as soon as possible.

CHECK MONITOR LAMP GROUP (Check items before starting) the

appropriate

When the engine is started, these monitor lamps will go off even if there are abnormalities.

CAUTION MONITOR LAMP GROUP (Caution items) If any abnormality occurs while the engine is running, the appropriate monitor lamp will flash to indicate the abnormality. *

C. CAUTION MONITOR LAMP GROUP (Emergency stop items) If any abnormality occurs while the engine is running, the appropriate monitor lamp will flash and the alarm buzzer will sound intermittently at the same time. *

If any monitor lamp flashes, stop the engine or run it at a low idling speed, and repair it immediately.

Even if any monitor lamp flashes, the machine

2-3

OPERATION D.

METER GROUP This group consists of engine water temperature gauge, torque converter oil temperature gauge, fuel gauge, speedometer, service meter and pilot display.

E. WARNING LAMP The warning lamp will flash when there is an abnormality in any item of group (B).

The warning lamp will flash and the alarm buzzer will sound when there is an abnormality in any item of group (C) or when the parking brake is applied, but directional lever is not in neutral.

SYSTEM CHECK 0

To check the monitor panel system, turn the starting switch to “ON” before starting the engine.

Then all monitor lamps, gauges and the warning lamp light up for about 3 seconds and the alarm buzzer sounds for about 1 second. Thee figures, “188”, are displayed on the speedometer while the monitor asystem is being checked. After that all lamps go off and the buzzer stops. If any monitor lamp doses not light up, ask your distributor to inspect that monitor lamp.

NOTE: Monitor lamp (A) dose not light up because it is not used on this machine.

Monitor lamps (B) light up only if the machine is equipped with the ground driven steering option.

*

When the starting switch is trurned to ON, if the directional lever is not at neutral, the warnign lamp will flash and the alarm buzzer will continue to sound, If this happens, return the lever to neutral. The lamp will go out and the buzzer will stop.

*

To chekc the monitor immediately when the engine is stopped, wait for at least 30 seconds after the engine is stopped.

2-4

LllAHOOC i1

OPERATION

A.

CHECK MONITOR LAMP GROUP (Check items before starting)

*

Do not rely on the “CHECK MONIOTR GROUP (Check before starting)” only for the check before starting. Always make the check by referring to the section on CHECK BEFORE STARTING.

B \

‘2

-2

0 1

A

1’

2

k /

3

-4

3

2

C

\

1.

Brake Oil Level Monitor This monitor indicates a low brake oil level. If the monitor lamp flashes, check the oil level and add brake oil as required.

2-5

OPERATION 2.

Engine Oil Level Monitor This monitor indicates a low level in the engine oil pan. If the monitor lamp flashes, check the oil level in the engine oil pan and add as required.

3.

Coolant Level Monitor This monitor indicates a low Radiator coolant level. If the monitor lamp flashes, check the coolant level and add water as required.

2-6

*

Park the machine on level ground and check.

*

Confirm that these monitor lamps light for about 3 seconds after turning the starting switch to ON. If any monitor lamp does not light, ask your distributor to inspect that monitor lamp.

I

OPERATION

B. CAUTION MONITOR LAMP GROUP (Caution items) If any abnormality occurs while the engine is running, the appropriate monitor lamp and the warning lamp will flash to indicate the abnormality at the same time.

1.

Battery charge monitor This monitor indicates an abnormality in the charging system while the engine is running. If the monitor lamp flashes, check the charging circuit. *

This monitor lamp flashes and the alarm buzzer sounds, when the starting switch is turned to ON immediately after the engine is started or immediately before the engine is stopped. It does not indicate a abnormality.

*

Confirm that this monitor lamp lights for about 3 seconds after turning the starting switch to ON, If the monitor lamp does not light, ask your distributor to inspect that monitor lamp.

t rl 2-7

OPERATION 2.

Fuel level monitor This monitor indicates there is less than 20 liters (5.28 gal.) of fuel in the tank. If the monitor flashes, add fuel.

C.

*

Park the machine on level ground and check.

*

Confirm that this monitor lamp lights for about 3 seconds after turning the starting switch to ON, If the monitor lamp does not light, ask your distributor to inspect that monitor lamp.

I

A

CAUTION MONITOR LAMP GROUP (Emergency stop items) If any abnormality occurs while the engine is running, the appropriate monitor lamp and the warning lamp will flash and the alarm buzzer will sound intermittently at the same time.

*

Confirm that these monitor lamps light for about 3 seconds after turning the starting switch to ON. If any monitor lamp does not light, ask your distributor to inspect that monitor lamp.

lADOl0

2-8

OPERATION 1.

Brake oil level monitor This monitor indicates a low brake oil level. If the monitor lamp flashes, check the oil level and add brake oil as required.

(0) A

2.

Engine oil pressure monitor This monitor indicates a low engine oil pressure.

If the lamp flashes, the engine oil pressure is below the lower limit. Immediately stop the engine. *

3.

This monitor lamp flashes and the alarm buzzer sounds, when the starting switch is turned to ON immediately after the engine is started or immediately before the engine is stopped. It does not indicated an abnormality.

Coolant level monitor This monitor indicates a low radiator coolant level.

Check the coolant level when the monitor lamp clashes, stop engine and add water/coolant concentrate as required.

Brake servo pressure monitor This monitor indicates a low brake oil pressure when the brake is actuated. If the lamp flashes, stop the machine immediately and check the brake lines.

LllAHO6 L

2-9

OPERATION

5.

Coolant temperature monitor This monitor indicates a rise in the cooling water temperature. When the monitor lamp flashes, run the engine with no load at mid-range speed until the green range of the engine water temperature gauge lights.

6.

Torque converter oil temperature monitor This monitor indicates a rise in the torque converter oil temperature. When the monitor lamp flashes, stop the machine and run the engine with no load at mid-range speed until the green range of the temperature gauge lights up.

7.

Ground driven steering monitor - if equipped If the engine stops when the machine is traveling, the lamp will light up to show that the ground driven steering has come into operation.

A *

2-10

WARNING! If the lamp lights up, move the machine immediately to a safe place and stop the machine.

Park the machine on level ground and check.

OPERATION D. METER GROUP (Pilot display) When the starting switch is turned ON, this lights

up to indicate that the display items are working.

8

9

8

10

5 1 6 2 7 3

4

1.

Parking brake pilot lamp

2-11

OPERATION 2.

Pilot lamp for working lamp This lamp lights up when the working lamps are switched on.

0

/IllI 3.

Transmission

cut-off selector pilot lamp

This lamp lights up when the transmission selector switch is turned to ON. *

4.

cut-off

If the monitor is ON and the left brake pedal the transmission will be is depressed, returned to neutral.

Ground driven steering pilot lamp When the machine is traveling, this lamp is on to show that the ground driven steering system pump is operating normally.

5.

Engine cooling water temperature gauge This gauge indicates the temperature of the cooling water. If the temperature is normal during operation, the green range (1) will light.

The lamps in the red range (2) light up to warn of overheating.

If the top lamp lights up, the alarm buzzer will sound, the warning lamp will flash and the coolant temperature monitor lamp will flash at the same time.

If a lamp in the red range lights up during operation, stop the machine and run the engine with no load at mid-range speed until the green range lights.

2-12

H 1

C

I

9 MlAHO59

OPERATION 6.

Torque

converter oil temperature gauge

This gauge indicates the temperature of the torque converter oil. If the temperature is normal during operation, green range (1) will light. The lamps in red range (2) light up to warn of overheating. If the top lamp lights up, the alarm buzzer will sound, the warning lamp will flash and the torque converter oil temperature monitor lamp will flash at the same time. If a lamp in the red range lights up during operation, stop the machine and run the engine with no load at midrange speed until the green range lights.

7.

21

I I

Yl I

1

Q

I

En

Fuel gauge This gauge indicates the amount of fuel in the fuel tank. If there is enough fuel in the tank while the engine is running, green range (1) lights. If red range (2) lights, there is less than 20 liters (5.28 gal.) of fuel in the tank.

When the red range lights, add fuel.

8.

Turn signal pilot lamp When the turn signal lamp flashes, the pilot lamp also flashes. *

9.

If the wiring disconnected,

of the turn signal lamp is the pilot lamp will flash faster.

High beam pilot lamp This lamp lights up when the head lamp is at high beam.

2-13

OPERATION 10. Speedometer This meter indicates machine.

the running

speed of the

JJ

&

Ll lAzOO3

11. Service

meter

This meter shows the total operation hours of the machine. The service meter advances while the engine is running - even if the machine is not traveling.

0

Refer to the section “SERVICE METER�. *

While the engine is running, the green pilot lamp on the service meter flashes to show the service meter advances.

ElSERVICE METER LllAJOOl

2-14

OPERATION SWITCHES

3 6

g

\ i

/

K 1

,

?

1.

2

5

WORKING LAMP SWITCH When the front and rear working lamps are turned ON, the pilot lamp and illumination lamp for the monitor panel will also light up.

Position (a) ON: Working lamps light up.

Position (b) OFF: Working lamps go off.

A

WARNING! When traveling on public roads, turn the working lamps off.

2-15

OPERATION 2.

STARTING

SWITCH 1

This switch is used to start or stop the engine.

OFF (1) Key insertion-withdrawal position. None of the electrical circuits activate.

The hazard lamp and the parking lamp will remain on, however, when the switch is turned OFF. To stop the engine, turn the switch to OFF.

ON (2) Charging and lamp circuits activate. Keep key at ON after starting.

LllAJ028

START (3) At this key position, the starting motor will crank the engine. Release the key immediately after starting, and the key will return automatically to ON. 3.

HAZARD LAMP SWITCH This switch is used in emergencies, such as when the machine breaks down.

ON (1): All turn signal lamps flash.

It

All turn signal lamps and the pilot lamp on the steering column flash, when this switch is put in ON.

OFF (2): All turn signal lamps are turned OFF.

A 4.

WARNING! Do not use this switch abnormality has occurred.

unless

HORN BUTTON When button in the center of the steering wheel is pressed, the horn will sound.

2-16

1 = ON

2 =

OFF

OPERATION 5.

LAMP SWITCHES (For head lamps, turn signal lamps, dimmer switch)

Lamp switch Position 1 Parking lamps light up.

Position 2 OFF Lamps go off.

Position 3 Clearance lamps, tail lamps and machine monitor panel lighting light up.

Position 4 Head lamps light up in addition to the lamps in position 3. *

The lamp switch can be operated regardless of the position of the lever.

Turn signal lever This lever operates the turn signal lamps.

1 LEFT TURN POSITION: Push lever FORWARD. 2 RIGHT TURN POSITION: Pull lever BACK. *

When the lever is operated, the turn signal pilot lamp will also light up.

*

When the steering wheel is turned to the neutral position, the turn signal lever will return automatically to OFF. If not, return the lever to OFF manually.

Dimmer switch This switches the head lamps between high beam and low beam.

Position A: Low beam Position B: High beam

2-17

OPERATION 6.

TRANSMISSION

CUT-OFFSELECTOR

SWITCH

This switch selects the operation of the left brake pedal. Normally, put this switch in ON position.

1.

OFF POSITION: Depressing the left brake pedal operates the wheel brakes only, like the right brake pedal.

2.

ON POSITION: Depressing the left brake pedal operates the wheel brakes and also returns the transmission to NEUTRAL. tif

\

LllAMOOe

the switch is in the ON position, the transmission cut-off selector pilot lamp will light up.

WARNING! If the machine has to be started on a slope, always turn the transmission cut-off selector switch to OFF and depress the left brake pedal. Then depress the accelerator pedal while releasing the left brake pedal to start the machine off slowly.

a

7.

I

ETHER START SWITCH This switch is used when starting the engine in cold weather.

C. ON POSITION: A fixed amount of ether (approx. 3 cc each time) is injected into the engine air intake to make it easier to start the engine in cold weather.

WARNING! Do not keep the switch at the ON position for more than 5 seconds.

A

D. OFF POSITION: When the switch is released, it automatically returns to the OFF position.

2-18

LllAM006

OPERATION 8.

FRONT WIPER SWITCH 1) 2) 3)

9.

OFF The wiper works at low speed.

The wiper works at high speed.

8

9

10

11 12 13

14

REAR WIPER SWITCH 1) OFF 2) The wiper works at low speed.

3) The wiper works at high speed.

Palm Cab

Sims Cab

2-19

OPERATION 10. WINDOW WASHER SWITCH 1) The washer sprays solvent on front window glass.

2) OFF 3) The washer sprays solvent on rear window glass.

L13DDOOt

OR

1) 2)

OFF The washer sprays solvent on the windows.

L13DD007

11. FRONT FLOOD LIGHT SWITCH 1) 2)

OFF ON

12. ACCESSARY

1) 2)

SWITCH

OFF ON

13. ROOM LAMP SWITCH 1) 2)

14.

OFF ON

ROOM LAMP SWITCH (Palm Cab only) 1) 2)

2-20

OFF ON

OPERATION 15. CIGARETTE LIGHTER This is used to light cigarettes. To use, push the lighter in. After a few seconds it will spring back.

At that time, remove the lighter and light your cigarette.

2-21

OPERATION LEVERS AND PEDALS

1.

DIRECTIONAL

LEVER

This lever is used to change the direction of travel of the machine.

1

2 N

*

Forward Reverse Neutral

*

The engine cannot be started if the directional lever is not at N (neutral).

*

When operating the directional lever, place your hand on a steering wheel and operate it by your fingers.

It is possible to change the length of the lever. the length, see For details of changing “TRANSMISSION CONTROL LEVERS” in Section 3.

2-22

02

LO7CHoo4

OPERATION 2.

SPEED CONTROL LEVER This lever machine.

controls

the

travel

speed

of the

This machine has a 4-FORWARD, 4-REVERSE speed transmission. Place the speed control lever in a suitable position to obtain the desired speed range. *

1st and 2nd speeds are used for working. 3rd and 4th speeds are used for traveling.

*

It is possible to change the length of the lever.

For details of changing the length, see “TRANSMISSION CONTROL LEVERS” in Section 3.

3.

SPEED CONTROL LEVER STOPPER

4th

L07CHOn’

This stopper prevents the speed control lever from entering the 3rd and 4th positions, when working.

Position 1 Stopper actuated.

L07CH006 Position 2 Stopper released.

4.

STEERING COLUMN TILT LEVER This lever allows the steering column to be tilted forward or backward.

Pull the lever up (B) and move the steering wheel to the desired position. Then push the lever down to lock (A) the steering wheel in position. *

A

Range of adjustment (stepless): 100 mm (3.9 in) WARNING! Stop the machine before adjusting the angle of the steering wheel.

LOSAMOlZ

2-23

OPERATION

7.

LIFT ARM CONTROL LEVER This lever is used to operate the lit? arm.

1 Raise 2 Hold The lift arm is kept in the same position.

3 Lower 4 Float The lift arm moves freely under external force.

When the lift arm control lever is pulled further from 1 position, the lever is stopped in this position until lift arm reaches the preset position of kick-out, and the lever is returned to the hold position.

8.

BUCKET CONTROL LEVER This lever operates the bucket.

1 Tilt 2 Hold The bucket is kept in the same position.

3

Dump

When the bucket control lever is pulled further from 1 position, the lever is stopped in this position until bucket reaches the preset position of positioner, and the lever is returned to the hold position.

LlOAZ067

2-25

OPERATION 9.

WORK EQUIPMENT

CONTROL LEVERS LOCK

This is used to lock the lift arm and bucket control levers.

4 b)

Lock Free WARNING! When parking or leaving the machine, orwhen performing maintenance, always lower the bucket to the ground, put the work equipment control levers in the hold position and place the lock lever in the “lock� position.

A

10. PARKING

BRAKE LEVER

This lever operates the parking brake. c) Lock: The brake is applied by pulling this lever, and the parking brake lamp lights up. d) Free: Push the button on the tip of the lever to release the parking brake.

A

WARNING! Always apply the parking brake when leaving the machine or parking it.

*

If the directional lever is placed in F (FORWARD) or R (REVERSE) with the parking brake applied, the warning lamp will flash and the alarm buzzer will sound.

*

When the parking brake is applied, the machine will not move even if the directional lever is placed in a travel position.

2-26

OPERATION WORK EQUIPMENT CONTROL LEVER (MON-LEVER TYPE) This lever is used to operate the lift arm and the bucket. a) b)

Raise Hold

The lift arm and the bucket are kept in the same position. c) d)

Lower Float

The lift arm moves freely under external force.

e) t)

Tilt Dump

*

When the work equipment control lever is pulled further from (a) position, the lever is stopped in this position until the lift arm reaches the preset position of kick-out, and the lever is backed to hold position.

*

When the work equipment control pulled further from (e) position, the stopped in this position until the reaches the preset position of positioner, and the lever is backed position.

lever is lever is bucket bucket to hold e

2-27

OPERATION CAB DOOR

HOLD OPEN LOCK - IF EQUIPPED

This lock can be used to hold the cab door open.

Open the door so that tip (2) of the lever is aligned with groove (1) for the lock, then pull down knob (3) as shown in the diagram.

When releasing the lock and closing the door, push up knob (3) and insert pin (4) securely in the groove. *

When using the hold open lock, be sure to apply the lock securely.

AIR CLEANER

SERVICE

INDICATOR

This device indicates clogging of the air cleaner element. When red piston (g) appears in the transparent part of the indicator, the element is clogged. Immediately clean element.

h

After cleaning, push indicator reset button (h) to return the red piston to its original position.

The service indicator is located on the engine hood behind the operator’s compartment.

‘g

FRAME The frame locking bar is used during maintenance or when transporting the machine. It locks the front frame and rear frame, and prevents the front and rear frames from moving at the articulation point. i = Lock j = Free

A

WARNING! Always use the locking bar for maintenance or when transporting the machine.

A

WARNING! Always remove the locking bar during normal travel operations.

2-28

LOCKING

BAR

Il7ARfMXl

OPERATION ENGINE SIDE DOOR LOCK The engine side door lock is used to hold the engine side door open when inspecting or maintaining the machine.

If the engine side door is opened fully, it is locked automatically. Pull the bottom of rod (a) at door side to close the door.

A

WARNING! When opning the engine side door for inspection or maintenance, always lock the door in position.

MAIN CIRCUIT BREAKER The circuit breaker prevents damage to the electrical components and wiring.

When the breaker has been actuated, press the reset button (b) to reset the system. However, if the circuit breaker is actuated again after the button is pressed, or the circuit breaker is frequently actuated, there may be a short circuit in the electrical system. In such cases, contact your distributor for repairs. *

Wait for 45 seconds after the circuit breaker is actuated before resetting it.

This is used to light cigarettes. To use, push the lighter in. After a few seconds it will spring back.

At that time, remove the lighter and light your cigarette.

HAJOOll

2-29

OPERATION FUSE BOXES The fuses protect the electrical equipment and wiring from burning out. If a fuse becomes corroded, coated with white powder or is loose in the holder, replace it. *

Replace a fuse with another of the same capacity.

A

WARNING! Before replacing a fuse, be sure to turn off the starting switch.

L08CH022

I

II 1Icrcll 21ool 3rO 4[0 5Io

P

8rLI

11 (0

14ro 15lrzl

2-30

OPERATION

Fuse arrangement and circuit Fuse box I (Inside, closest to seat) No.

Fuse capacity

1

20A

Starting switch

2

10A

Hazard lamp

3

10A

Head lamp. LEFT

4

Circuit

10A I

Head lamp, RIGHT I

5

10A

Left side running lamp

6

10A

Right side running lamp

7

20A

Light, main (Head, Parking, Side clearance & Tail lamps

8

10A

Turn signal lamp

9

10A

Brake light and Back-up lamp

10

10A

Transmission

11

10A

Horn

12

20A

Working lamp

13

10A

Electronic instrument (Monitor Lamp)

14

10A

Bucket positioner, Boom Kick-out (Positioner)

15

5A

Engine shut-off motor

control valve (T/M valve)

Fuse box II (Outside, furthest from seat) No.

Fuse capacity

1

20A

Air conditioner

(Fan outside unit)

2

20A

Air conditioner

(Fan inside unit)

3

10A

Radio, Room lamp

4

10A

Cigarette lighter

5

10A

Rear wiper and washer

6

10A

Front wiper and washer

7

10A

Auxiliary

Circuit

OPERATION OPERATOR’S SEAT RIGID TYPE Operator’s seat adjustment should be checked at the beginning of each shift and when operators change.

C. BACKREST ADJUSTMENT

A

Move lever (3) upward, move the backrest to the best position and release the lever. The backrest can be set to 12 steps.

WARNING! Park the machine in a safe place and stop the engine when canying out adjustment of the operator’s seat.

A. FORWARD-BACKWARD

I

ADJUSTMENT

Move adjustment lever (1) to the right, move the seat to the best position and release the lever. The seat can be moved forward or backward within a range of 140 mm (5.5 in) in 8 stages.

B. SEAT HEIGHT ADJUSTMENT Move adjustment lever (2) up, set the seat to the desired height and release lever.

The seat can be set within 50 mm in 5 stages.

BUCKET TYPE SEAT (OPT) Operator’s seat adjustment should be checked at the beginning of each shift and when operators change.

A

WARNING! Park the machine in a safe place and stop the engine when carrying out adjustment of the operator’s seat.

BACKREST ADJUSTMENT Pull lever (5), move the backrest to the best position and release the lever. The backrest can be set to 11 steps.

SEAT HEIGHT ADJUSTMENT

FORWARD-BACKWARD

ADJUSTMENT

Move adjustment lever (1) to the right, move the seat to the best position and release the lever. The seat can be moved forward or backward within a range of 140 mm (5.5 in) in 7 stages.

SEAT ANGLE ADJUSTMENT Move adjustment lever (2) up, set the seat to the desired height and release lever.

The seat can be tilted up or down about 3”.

SEAT CUSHION ADJUSTMENT Rotate grip (3) under the seat to adjust scale (4) on the cushion to your own weight. (50 to 120 kg)

2-32

Move lever (6) upward, set the seat to the desired height and release the lever.

The seat can be set within 50 mm.

I

OPERATION SEARS SEAT Operator’s seat adjustment should be checked at the beginning of each shift and when operators change.

A

WARNING! Park the machine in a safe place and stop the engine when carrying out adjustment of the operator’s seat.

A. FORWARD-BACKWARD

ADJUSTMENT

Move adjustment lever (1) to the right, move the seat to the best position and release the lever. The seat can be moved forward or backward within a range of 140 mm (5.5 in) in 7 stages.

B. SEAT ANGLE ADJUSTMENT Move adjustment lever (2) up, set the seat to the desired angle, and release the lever. The seat can be tilted up or down by about 3”.

C. WEIGHT ADJUSTMENT Rotate adjustment knob (3) located in front of the seat, to adjust ride scale (4) to your own weight. The weight adjustment range is 50 to 120 kg (110.2 to 264.6 lb).

D. BACKREST

L13BH016

TILT ADJUSTMENT

Pull adjustment lever (5) up, move the backrest to the best position and release the lever. The backrest can be set within a range of 22“ in 11 steps.

E. HEIGHT ADJUSTMENT

1.

2.

3.

4.

5.

6.

Forward-backward adjustment lever Seat angle adjustment lever Weight adjustment knob Ride indicator pointer Backrest tilt adjustment lever Height adjustment lever

Move adjustment lever (6) upward, set the seat to the desired height and release the lever. The seat height can be set within a distance of 50 mm (2 in) in 4 stages.

2-33

OPERATION

KAB SEAT WEIGHT ADJUSTMENT For maximum comfort and protection from vibration it is important that the suspension is set correctly for your weight.

Turn the adjuster knob (1) until the indicated weight (seen inside the transparent knob) corresponds to your weight in kilograms.

The optimum adjustment is for the suspension to be in the middle of the vertical stroke (“mid-ride” position) when normally seated.

HEIGHT ADJUSTMENT After adjusting for weight, the seat height and cushion angle may be adjusted by lifting levers (2 and 3). The front and rear of the seat are adjusted independently.

BACKREST ANGLE ADJUSTMENT Lii lever (4) set backrest to desired angle and release lever.

FORE AND AFT ADJUSTMENT Lift control (5) slide seat to the desired position.

Ensure mechanism is fully engaged after adjustment.

HEADREST ADJUSTMENT

(IF EQUIPPED)

The headrest (6) height is adjusted by sliding up or down, and the angle by pivoting backwards or forwards.

2-34

X13BHOI

OPERATION

RIGHT SIDE ARMREST HEIGHT Loosen mount bolts (1) to move the armrest to the desired position and tighten the bolts.

ANGLE ADJUSTMENT Loosen mount bolts (2) to move the armrest to the desired angle and tighten the bolts.

/

FORWARD-BACKWARD

L13BH018

ADJUSTMENT

Open the armrest, then loosen bolts (2) to the desired position, and tighten the bolts.

L13BH032

2-35

.I

OPERATION SEAT BELT

A

WARNING! When operating a machine equipped with a ROPS, be sure to use the seat belt.

A

WARNING! Before fastening the seat belt, inspect the mounting brackets and belt for abnormal conditions.

3’ Fasten the belt and remove manner.

1.

2.

Adjust the seat so that the brake pedal can be depressed all the way with the operator’s back against the backrest.

Rigid and Bucket Type Seats

After positioning the seat, install the tether belt (1). With the seat unoccupied, tense the belt slightly across the seat and install.

A 3.

it in the following

WARNING! Check that there are no kinks in the belt.

Sit in the seat. Hold buckle (2) and insert tang (3) into the buckle. Check that the belt has locked by pulling it.

4.

When removing the belt, raise the tip of the buckle lever to release it.

*

When leaving the operator’s seat, release the seat belt and hang it over the arm rest.

*

Fasten the belt across your body without kinking it. Adjust the lengths of the belt on both the buckle and tang ends so that the buckle is located at the mid-point of your body front.

Ll3t3HOl!

Sears and KAB Type Seats

Adjust the belt length in the following manner.

1.

To shorten the belt, pull the free end of the belt at either the buckle or tang end or at both ends.

2.

To lengthen the belt, pull the belt while holding it at a right angle to the buckle or tang.

*

Inspect the seat belt mounting hardware for tightness. Retighten any loose bolts to a torque of 2 3 kgm (14 - 22 Ibf ft / 19 - 30 Nom).

*

If the seat belt is worn or frayed or if the belt buckle and/or tang or any of the mounting brackets are damaged or deformed, replace the seat belt immediately.

Li3BHOZO

2-36

OPERATION DRAWBAR PIN 1.

Align protrusion (A) of drawbar pin (C) with gr6ov6 (B) of the bduntetweight, then in&t and rotate 180�.

I

I 2.

To prevent the drawbar pin from rotating, fold the knob of the drawbar and set in position.

*

When removing, remove in the opposite order.

A

LO9AVOOl

WARNING! If step 1 and 2 are not carried out properly, the pin may come out and be lost.

LO9AVOOZ

rl

2-37

OPERATION CAB HEATER AND DEFROSTER

- IF EQUIPPED

CONTROL PANEL It is possible to use the cab heater to good effect in dusty jobsites. The outside air is passed through the filter and is sent to the operator’s cab to increase the pressure inside the cab. In this way, dust is prevented from entering, so comfortable operating conditions are always maintained for the operator.

1.

FAN SPEED SWITCH (1)

This switch controls the air flow when the cab heater is used for heating. *

It has three air flow control levels: LO (Low), ME (Medium) and HI (High)

*

If the outside air is extremely dusty, set the fan speed switch to the HI position. This will pressurize the cab and prevent the dust from entering.

2.

FOOT / DEFROSTER SELECT LEVER (2)

This lever is used to control the air flow to the foot and defroster vents.

3.

AIR INTAKE SELECTOR LEVER (3)

This lever switches the air intake port when heating. *

FRESH: Operate the lever to the right.

Fresh air is taken in from outside in addition to the air inside the compartment. This is used for ordinary heating and when pressurizing the inside of the cab.

*

RECIRC: Operate the lever to the left.

Only the air inside the compartment is mainly used for quick heating.

is used. This

1= Lock 2= Free *

The effectiveness of the heating system can be increased by selecting the most suitable vent.

*

Do not turn the fan speed switch on when all the vents are closed.

2-38

I

U3EZOl:

OPERATION CONTROL PANEL It is possible to use the cab heater to good effect in dusty jobsites. The outside air is passed through the filter and is sent to the operator’s cab to increase the pressure inside the cab. In this way, dust is prevented from entering, so comfortable operating conditions are always maintained for the operator.

1. FAN SPEED SWITCH This switch controls the air flow when the cab heater is used for heating. *

It has three air flow control levels: LO (Low), ME (Medium) and HI (High)

*

If the outside air is extremely dusty, set the fan speed switch to the HI position. This will pressurize the cab and prevent the dust from entering.

13EZOOE

2. TEMPERATURE

CONTROL LEVER

This lever is used to control cooling or heating. f

*

the temperature

for

The farther the lever is moved to the left, the lower the temperature of the air blown out from the vents.

DEFROS

The farther the lever is moved to the right, the higher the temperature of the air blown out from the vents.

3. AIR INTAKE SELECTOR LEVER

U3EZ007

This lever switches the air intake port when heating. *

FRESH: Operate the lever to the right.

Fresh air is taken in from outside in addition to the air inside the compartment. This is used for ordinary heating and when pressurizing the inside of the cab.

*

RECIRC: Operate the lever to the left.

Only the air inside the compartment is mainly used for quick heating.

is used. This

2-39

OPERATION METHOD

OPERATION

OF OPERATION

OF CONTROL PANEL

SWITCH AND LEVER POSITIONS PURPOSE Fan Speed Switch

Quick

HI

Normal

HI - LO

Temperature Control Lever Full to near right

Air Intake Selector Lever Left

Heating

Defrosting

Ventilation or Pressurizing

HI

HI - LO

Center to near right

Right

Center to near right - Full right when carrying out quick defrosting or demisting

Right

Full left

Right

AIR VENT SELECTION VENT POSITION PURPOSE Face (1)

Foot (2)

Defrost (3)

Open or closed

Open

Open or closed

Defrosting

Closed

Open or closed

Open

Ventilation

Open

Open

Open

Heating

*

The effectiveness of the heating system can be increased by selecting the most suitable vent.

2-40

*

Do not turn the fan speed switch on when all the vents are closed.

OPERATION

CAB HEATER, DEFROSTER AND AIR CONDITIONER - IF EQUIPPED CONTROL PANEL It is possible to use the cab heater and air conditioner to good effect in dusty jobsites. The outside air is passed through the filter and is sent to the operator’s cab to increase the pressure inside the cab. In this way, dust is prevented from entering, so comfortable operating conditions are always maintained for the operator.

1-02

1. FAN SPEED SWITCH

/

This switch controls the air flow when the cab heater and air conditioner is used for heating or cooling. f

It has three air flow control levels: LO (Low), ME (Medium) and HI (High)

*

If the outside air is extremely dusty, set the fan speed switch to the HI position. This will pressurize the cab and prevent the dust from entering.

2.

AIR CONDITIONER

Ll3FOo1a

\ n i

DEFROS

SWITCH

This is the switch for cooling.

ON:

Push the button to carry out dehumidification and cooling. The blue lamp lights up to indicate that the cooling system is on.

L13EZ007

4. AIR INTAKE SELECTOR LEVER

OFF: If the system is ON and the button is pressed again, the switch returns to its original position and the air conditioner is switched off.

This lever switches cooling or heating.

*

*

Turn the air conditioner switch turning the fan speed switch on.

3. TEMPERATURE

on after

*

*

The farther the lever is moved to the left, the lower the temperature of the air blown out from the vents.

port when

FRESH: Operate the lever to the right.

Fresh air is taken in from outside in addition to the air inside the compartment. This is used for ordinary heating or cooling and when pressurizing the inside of the cab.

CONTROL LEVER

This lever is used to control the temperature for cooling or heating. *

the air intake

RECIRC: Operate the lever to the left.

Only the air inside the compartment is used.

This is mainly used for quick heating or cooling.

The farther the lever is moved to the right, the higher the temperature of the air blown out from the vents.

2-41

OPERATION METHOD

OF OPERATION

OPERATION OF CONTROL PANEL

PURPOSE

I

SWITCH AND LEVER POSITIONS Fan Speed Switch

Air Conditioner Switch

HI

ON

Full left

Normal

HI - LO

ON

Full left to near center

Right

and

HI - LO

ON

Center to near right

Right

Quick

HI

OFF

Full to near right

HI - LO

OFF

Center to near right

HI

ON

HI - LO

OFF

Quick

Temperature Control Lever

Air Intake Selector Lever Left

Cooling

Dehumidfying heating

Left

Heating Normal

Defrosting

Ventilation or Pressurizing

Right

Center to near right - Full right when carrying out quick defrosting or demisting

Right

Right

Full left

AIR VENT SELECTION

VENT POSITION PURPOSE Face (1)

Foot (2)

Defrost (3)

Cooling

Open

Open or closed

Closed

Heating

Open or closed

Open

Open or closed

Defrosting

Closed

Open or closed

Open

Ventilation

Open

Open

Open

*

2-42

The effectiveness of the heating conditioning system can be increased selecting the most suitable vent.

air by

f

Do not turn the fan speed switch on when all the vents are closed.

OPERATION PRECAUTIONS FOR USING AIR CONDITIONER *

When cooling, change the air occasionally.

0

Smoking in the air conditioned cab will cause your eyes to get sore. While smoking, open the window to let the smoke out of the cab.

0

While using the air conditioner, window once every hour.

*

Be careful not to overcool the cab.

0

The cab should feel cool when entering it from the outside (5°C lower than the outside temperature). It is not good for the health to have the temperature in the cab too low. careful consideration to Always give temperature regulation.

HANDLING AIR CONDITIONER

IN SEASON

To use the air conditioner comfortably during its season, ask your distributor to check the air conditioner and add refrigerant if necessary. l

The standard cleaning interval for the cab air filter is every 100 hours, but if it becomes clogged, it will be impossible to pressurize the inside of the cab. In addition, it may cause failures, so check and clean the air filter immediately. For details of cleaning the air filter, refer to “MAINTENANCE” in Section

l

If a large amount of dirt or dust collects on the condenser, the cooling capacity drops, so check and clean when necessary. For details, of cleaning the air conditioner condenser, refer to “MAINTENANCE” in Section 3.

open the

HANDLING OFF-SEASONS

AIR

CONDITIONER

IN

To lubricate each part of the compressor during the off-seasons, operate the air conditioner for a few minutes two or three times a month.

2-43

OPERATION LOCKING

FILLER CAPS

FUEL TANK FILLER CAP A locking filler cap is located on the fuel tank filler opening. Open and close the locking cap as follows, using the starting switch key: To open the cap 1.

Insert the key into the cap. *

2.

Insert the key as far as it will go up to the shoulder (1). If the key is turned before it is inserted all the way, it may bent or break.

Turn the key clockwise (a), align the match mark on the cap with the rotor groove, then remove the cap.

To lock the cap 1.

Turn the cap into place. *

2.

2-44

Insert the key as far as it will go up to the shoulder (1). If the key is turned before it is inserted all the way, it may bent or break.

Turn the key counterclockwise the key out.

(b) and take

a

OPERATION

HYDRAULIC

TANK

FILLER

CAP

A locking filler cap is located on the hydraulic tank filler opening. Open and close the locking cap as follows, using the starting switch key: To open the cap 1.

Insert the key into the cap.

Ir

Insert the key as far as it will go up to the shoulder (1). If the key is turned before it is inserted all the way, it may bent or break.

LO222071

2.

Turn the key counterclockwise (C) and bring the rotor groove in line with the aligning mark (2) on the cap. Turn the cap slowly until a “clicking” sound is made. This releases the lock and allows the cap to be opened.

I ‘in( ‘w

To lock the cap 1.

Turn the cap into place. *

2.

Insert the key as far as it will go up to the shoulder (1). If the key is turned before it is inserted all the way, it may bent or break.

1

I

Lo2zi!o7s

Turn the key clockwise and take the key out. *

When the cap is locked vandalism, it rotates freely.

against

LO22208C

2-45

OPERATION CHECK BEFORE STARTING Pre-operation checks forestall machine trouble. Never neglect them.

WALK-AROUND

CHECK

Look around the machine and under the machine to check for loose nut or bolts, collection of dirt, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check also for loose wiring, play, and collection of dust at places which reach high temperatures.

1. Check wear of bucket.

2. Check around transmission

case joints for oil

leak.

3. Check around brake system for oil leak.

4. Check tightness of air cleaner mounting bolt.

5. Check tightness of battery terminal.

6. Check radiator for water leak.

7. Check around the engine for water and oil leaks.

8. Check around axle for oil leak.

9. Check hydraulic tank joint for oil leak.

10. Check for oil leak at high pressure hose and high pressure hose joints.

11. Check tire for wear and damage.

CHECK 1.

MONITOR

Turn the starting switch to “ON” (2).

(1 = OFF, 2 = ON, 3 = START)

2.

PANEL

1 I

Check that all monitor lamps, gauges and the warning lamps light up for about 3 seconds and the alarm buzzer sounds for about 1 second as described under “SYSTEM CHECK” in this section. *

*

If any monitor lame does not light up, ask your distributor to inspect that monitor lamp.

UlAJO3r

Always make the check by referring to this section on CHECK BEFORE STARTING.

I

2-46

LllAHO6:

OPERATION

CHECK

AND REFILL

COOLANT

Remove radiator cap (1) on rear machine body, and check that coolant is filled up to the depth indicated by shadowed portion. If not, add coolant. *

If the volume of coolant added is more than usual, check for possible water leakage.

*

Confirm that engine oil is not present in the coolant.

*

Use a mixture of 50% water ethyleneglycol base antifreeze.

A

and

\ L \

50%

==L06AM038

WARNING!

Do not remove the cap while coolant is hot. Hot coolant may spout out. When removing the radiator cap, lift the lever to relieve the inner pressure.

L06AM039

CHECK

AIR CLEANER

SERVICE

INDICATOR

When the air cleaner element is clogged, the red piston of the service indicator (1) reaches service level and gets locked.

In this case, clean the element referring to “WHEN REQUIRED SERVICE�.

After cleaning the element, push the button to reset the red piston.

2-47

OPERATION CHECK

OIL LEVEL AND REFILL

1.

Open the engine side cover at the rear right side of the machine.

2.

Use dipstick (G) to check the oil level.

3.

The oil level should be between mark L and H. If necessary, add oil at the oil filler port (F).

*

Never operate the engine with the oil level below the L mark or above the H mark.

*

The type of lubricant used depends on the ambient temperature. Select according tot eh table “FUEL, COOLANT AND LUBRICANTS”.

*

When checking the oil level, park on a level surface and make check before starting the engine or more after the engine is shut

IN ENGINE

OIL PAN

LIZAD

the machine an oil level or 5 minutes down.

LlZAD09

CHECK

FUEL LEVEL AND REFILL

1.

Check the fuel level using the fuel gauge (G) on the monitor panel.

2.

Upon completion of work, add additional fuel at the filler port (F) until the tank is full.

Muel

A

capacity:

FUEL

1700 (44.9 U.S. gal.)

WARNING! When adding fuel, never let the fuel overflow. This may cause a fire.

LlZBD03f

2-48

OPERATION

CHECK AND REFILL OIL IN BRAKE OIL TANK 1.

Check that the oil level in the tank (1) located on the side of the hydraulic tank is between the MAX and MIN marks.

2.

Open cap (2) and refill with engine necessary.

oil, if

*The type of lubricant used depends on the ambient temperature. Select according to “FUEL, COOLANT AND the table LUBRICANTS”.

A

WARNING! Always use engine refill the brake oil tank.

oil to

DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR With the engine shut-off, open the drain valve (1).

Turn the valve counterclockwise approximately 1% to 2 turns until draining occurs. Drain the filter sump of water until clear fuel is visible. *

Do not over tighten the valve. Over tightening can damage the threads.

*

Turn the valve clockwise approximately 2 turns to close the drain valve.

*

Even if a filter/water separator is installed be sure to check the fuel tank to remove water and sediment in the fuel.

1M to

1

1

LlZBMOll 3

Ll2BMOO!

2-49

OPERATION ADDITIONAL CHECKS A.

Check that parking brake works properfy.

B.

Check that brakes work properly.

Check that engine exhaust gas color and sound are normal.

G. Check that properly.

C. Check that horn sounds properly.

D. Check that lamps flash properly; check for dirt or damage.

E.

F.

Check direction of rear view mirror; check for dirt or damage.

Check the following l Battery 0 Starting motor l Alternator

2-50

points carefully.

and

instruments

work

H.

Check steering play: check that steering works properly.

I.

Check that back-up buzzer sounds properly.

J.

Check the air intake piping for damage, cracked hoses, and loose clamps.

CHECK ELECTRICAL WIRING Check for any sign of disconnection or short circuit in the electric wiring. Check also for loose terminals and tighten any loose parts.

gauges

OPERATION OPERATING YOUR MACHINE BEFORE STARTING THE ENGINE 1.

Carry out an initial inspection. (For details of the inspection, see CHECK BEFORE STARTING.)

2.

With your back against the backrest of the operator’s seat, adjust the seat position so that the brake pedal can be easily depressed.

3.

Is parking brake lever (1) in lock position?

4.

Is directional

lever (2) in N (neutral) position?

Sr The engine will not start while the directional lever (2) is in any position other than N (neutral).

---._ 9

F M~:-~-~~---.--

-

p;_____._._.-

..:._...

c. .. . .1..

.’ . --.

. . . . . . . :.

.,__ __ _....-

-.....

..‘.._._

2-51

OPERATION 5.

Are work equipment control levers (3) locked by safety lock (4)?

6.

Turn the starting switch ON and check that the pilot lamp lights up.

I

STARTING

LlOAZ074

ENGINE

Depress accelerator pedal (1) lightly.

Turn the key of starting switch (2) to the START position to start engine.

When engine is started, release the key of starting switch (2) and the key will return automatically to ON. *

If engine will not start, repeat the starting procedure after about 2 minutes.

*

Do not leave the key in START for more than 20 seconds.

f

To start engine in cold weather.

COLD WEATHER OPERATION.

refer to

4

,’

A A = OFF B = ON

2-52

2.

Y7

_______ _____--. C

C = START

A = OFF

B = ON

C = START

OPERATION

SPECIAL STARTING When starting after running out of fuel, fill with fuel, then fill the fuel filter cartridge with fuel and bleed the air from the fuel system before starting.

Refer to FUEL FILTER in every 500 hours services.

COLD WEATHER STARTING When starting the engine in low temperatures, do as follows.

1.

Turn the key of starting switch (1) to the START position.

2.

Move ether start switch (2) to the ON position, then release it immediately. Do NOT hold it at the ON position for more than 5 seconds. This will cause failure of the ether start valve solenoid.

*

If the engine does not start, repeat this 2-3 times.

*

If the engine does not start, repeat the starting procedure after about 2 minutes.

1

/

LllAMO94

C

A = OFF

B = ON

C = START

I

2-53

OPERATION 3.

When the engine starts, release the key of starting switch (1) and the key will return automatically to the ON position.

*

Do not leave the key in START for more than 20 seconds.

*

,B

I

,/ ,/

If the engine does not start, repeat the starting procedure after about 2 minutes.

LllA JO3CI , = OFF

A *

B = ON

C = START

WARNING! Never operate the ether start switch (2) except when starting the engine.

*

Remove the ether cylinder when it is unnecessary in summer.

The ether cylinder can be used for about 230 times, (Amount of ether injected: 3 cc, total capacity for one cylinder: 710 cc.)

*

When ambient temperature is below -25”C, keep the ether cylinder in a place where the temperature is normal.

*

Before changing the ether cylinder always clean out the valve area where cylinder is installed, and replace the gasket at the same time.

*

The standard specification machine is designed to work in an ambient temperature down to -20” C (4°F).

A

WARNING! cylinder.

Carefully

handle

the

ether

l

Never give cylinder access to fire.

0

After used, do not throw it in fire nor drill a hole in it.

a

Do not store it at places where temperature may rise over 40°C.

the

*

When operating the machine at temperatures below -20°C special equipment is needed.

Contact your distributor for details.

0

Never put ether gas on the skin nor breath it in.

*

For machines where the air dryer is installed as an option, in cold temperatures below -10°C (+ 14”F), after the machine has been stopped, operate the machine for at least 10 minutes after starting before moving the machine.

0

Do not leave it on the operator’s seat.

0

Do not leave it at places where children can reach or play with it.

0

NEVER use ether together with a preheating device for the air intake.

2-54

OPERATION

COLD WEATHER

WARM-UP

PROCEDURE approximately 5 seconds, then return the lever to the neutral position and hold it for approximately 2 seconds. Repeat this operation to warm up the work equipment circuit.

When starting the engine the engine in cold weather, do not start operations immediately. First carry out the following.

Ambient temperature -20°C (-4” F) -10°C (14°F) 0” C (32” F)

*

Warm-up time 15 minutes 10 minutes 5 minutes

;;t;the

A

*

Avoid sudden acceleration of the engine before the warming-up operation is completed.

*

Do not idle the engine continuously 20 minutes.

2.

After completing the warming-up operation for the engine, warm up the work equipment circuits.

3.

engine speed gradually from the idling

WARNING! If the machine is operated suddenly before the warming-up operation is carried out, the work equipment may be damaged. The warming-up operation is also mandatory for safety reasons.

Warm up the steering circuit as follows.

for more than

1)

Move the lift arm control lever slowly to the RAISE position and raise the bucket slightly.

2)

Move the lift arm control lever slowly to the LOWER position and lower the bucket slightly.

3)

Repeat the above operation several times and gradually increase the amount you move the lift cylinders.

4)

Repeat Steps 1) - 3) for the bucket control lever to warm up the work equipment circuit. * Run the engine with the throttle at the l/3 position or below.

3)

Raise the bucket 10 - 30 cm (3.7 - 11.8 in) from the ground, operate the bucket control lever to the tilt position, relieve the circuit for

A

WARNING! If this operation is carried out when the oil temperature is still low, even when the steering wheel is turned and stopped, there may be a time lag before the chassis turns or stops. In such cases, carry out the warming-up operation in a large open area. In addition, use the safety bar to ensure safety. In this case, do not relieve the circuit for more than 5 seconds.

4.

Turn the steering wheel slowly to the left and right to warm up the oil inside the steering valve.

Repeat this operation about 10 times.

*

Turn the steering wheel a short distance, then stop it, and check that the chassis stops according to the amount the steering wheel is turned.

*

The recommended oil for the work equipment hydraulic system depends on the ambient temperature. Select oil according to the table under “LUBRICANTS, FUEL AND COOLANT” in Section 3.

2-55

OPERATION

CHECKS After starting make the following

AFTER

checks.

1.

Depress accelerator pedal (1) lightly and run the engine with no load at mid-range speed for about 5 minutes.

2.

After warm-up run is completed, lamps for proper operation.

*

Continue to run the engine at light load until the green ranges of the engine water temperature gauge and torque converter oil gauge are indicated.

3.

Check if the exhaust color is normal or whether there is any abnormal noise or vibration.

*

Avoid abruptly accelerating completion of warm-up.

*

Do not run the engine at low idle continuously more than 10 minutes.

check monitor

the engine until the

for

MOVING 1.

Check that a warning item is not displayed on the monitor panel.

2.

Free the safety lock for work equipment lever and bring the work equipment traveling posture.

2-56

STARTING

control to the

MACHINE

OFF

OPERATION 3.

Depress the right brake pedal (l), and release the parking brake using the parking brake lever (2)..

LlOAZ075 4.

Set speed control lever (3) and directional (4) to the desired position.

5.

Release right brake pedal (l), then depress the accelerator pedal (5) to move the machine off.

A

lever

WARNING! If the machine has to be started on a slope, always turn the transmission cut-off selector switch to OFF and depress the left brake pedal. Then depress the accelerator pedal while releasing the left brake pedal to start the machine off slowly.

Lo7cHoo9

2-57

OPERATION SHIFTING

GEAR

Move speed control lever (1) to the desired position. *

To use 1st or 2nd speeds for digging and loading operations, actuate speed control lever stopper (2).

L07CHOOf

4th

L07CHOOE

SHIFTING

BETWEEN

FORWARD

AND REVERSE

There is no need to stop the machine even when switching between FORWARD and REVERSE. Place directional

A A

lever (1) in the desired position.

Before changing WARNING! check that it is safe.

direction,

Never change between WARNING! FORWARD and REVERSE at high speed.

LO7CH012

2-58

I

OPERATION STEERING MACHINE When traveling, machine.

use steering wheel

(1) to turn the

*

Wiih this machine, the front frame is joined to the rear frame at the center of the machine by the center pin. The front and rear frames bend at this point, and the rear wheels follow in the same track as the front wheels when turning.

*

Turn the steering wheel lightly to follow the machine as lt turns. When turning the steering wheel fully, do not turn it beyond the end of the stroke.

A A

WARNING! It is dangerous to turn the machine suddenly at high speed, or to turn on steep hills.

WARNING! If the engine stops when the machine is traveling, the steering wheel becomes heavy, so do not stop the engine.

This is particularly dangerous on slopes, so the engine must never be stoped when traveling on slopes.

If the engine should stop, stop machine immediately in a safe place.

the

2-59

OPERATION TO STOP THE MACHINE 1.

Release accelerator pedal (l), and depress brake pedal (2) to stop the machine.

2.

Place directional lever (3) in N (neutral).

3.

Pull parking brake lever (4) to apply the parking brake. f

When the parking brake is applied, the transmission is automatically returned to neutral.

4.

Fit safety lock (A) on the directional lever.

5.

Operate work equipment control lever (5) and lower the bucket to the ground, then lock safety lock lever (6) for work equipment control lever.

A A A

WARNING! Stop the machine in a safe place on firm level ground.

WARNING! If the machine has to be stopped on a slope, put blocks under the wheels.

WARNING! In addition, dig the bucket into the ground to increase safety.

A/

LlOAZ073 L07CH031

LlOAZ074

2-60

OPERATION TO STOP THE ENGINE 1.

Run the engine at low idling speed for about 5 minutes to allow it to gradually cool down.

2.

Return starting switch (1) to the OFF position and remove the key.

*

If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency.

*

In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop it.

I

..

\_.J

___

1

LllAMlO(1

1 = OFF

2 = ON

3 = START

OPERATIONS AFTER STOPPING ENGINE Walk around the machine and check the work equipment and tires, also check for oil or coolant leakage. If any abnormalities are found, repair them.

Fill the fuel tank.

3.

Check the engine compartment for foreign matter and debris. If found, remove the matter and/or debris to avoid a possible fire hazard.

4.

Remove any mud stuck to the underside of the machine.

2-61

OPERATION OPERATIONAL PRECAUTIONS WORKING IN DUSTY LOCATIONS 1.

Inspect the dust indicator to se whether the air cleaner is blocked up. Clean the air cleaner as soon as it becomes dirty.

2.

Clean the radiator core become blocked up.

3.

Clean or replace the fuel filter as soon as it becomes dirty.

4.

Clean the electrical equipment, particularly starting motor and alternator, to prevent accumulation of dust.

0

so that

it does

0

When welding, be careful of the following: 1) Turn OFF the power (starting switch).

not

the the *

2)

Do not continuously

apply more than 200 V.

3)

Install the ground cable at least 1 m from the range to be welded.

4)

Take care not to install the seals between the grounded point and the range to be welded.

Use ordinary automobile washer fluid. Be careful not to let dirt or dust get in.

When installing a car radio and a walkie-talkie or citizen band, contact your distributor.

GREASING THE ROD END

0

When washing the machine, take care not to splash water over the electrical equipment. If it is soaked with water, it may not operate normally.

Because the rod end is of the oilless type, no greasing is required, although a grease nipple is fitted to the rod end of the lever linkage.

0

After disconnecting a connector, cover it with a vinyl bag to prevent oil or dust from sticking to its contact section.

The rod end should be greased only when it becomes stiff after using it for a long span of time.

MAXIMUM DEPTH OF WATER When working in water or on swampy ground, do not let the water come above the bottom of the axle housing. f

After finishing the operation, wash and check the lubricating points.

L07FM035

1 = Axle housing

2-62

OPERATION

IF WHEEL

BRAKE

DOES NOT WORK

If the machine is not stopped by depressing brake pedal, use the parking brake to stop the machine.

PRECAUTIONS

WHEN

DRIVING

LOWER THE CENTER OF GRAVITY WHEN TURNING When turning on slopes, lower the work equipment to lower the center of gravity before turning. It is dangerous to turn the machine with the work equipment raised.

BRAKING ON DOWNHILL SLOPES When going down slopes, put the speed control lever in a low gear position (the same position as when driving up the slope). Make full use of the engine to slow the machine, and use only the right brake pedal.

If the speed control lever is not placed in a proper speed position, the torque converter oil may overheat.

UP OR DOWN SLOPES If it overheats, place the speed control lever in the next lower gear speed to lower the oil temperature.

If the temperature gauge does not indicate the green range of the scale even with the lever in the 1st speed position, stop the machine, place the lever in neutral, and run the engine at medium speed until the gauge indicates the green range.

IF ENGINE STOPS If the engine stops on a slope, depress the right brake pedal fully. Next, lower the work equipment to the ground and apply the parking brake. Then put the directional and speed control levers in neutral, and start the engine again. (If the directional lever is not in neutral, the engine will not start).

2-63

OPERATION POSSIBLE

WORK

USING

LOADER

Various types of attachments are available to extend the range of application beyond the applications described below.

EXCAVATION 0

When loading piled soil or blasted rock, drive the machine forward as follows to load. To prevent cutting of the tires caused by the tires slipping, be careful of the following points during the operation.

*

Always keep the operating move any fallen rocks.

*

When working with stockpiles, operate the machine in 1st or 2nd, operate the machine in 1st when loading blasted rock.

jobsite flat, and re-

1. When driving the machine forward and lowering the bucket, stop the bucket about 30 cm (0.9 ft) from the ground, then lower it slowly. *

If the bucket hits the ground, the front tires will come off the ground, and the tires will slip.

2. Shift down immediately in front of the material to be loaded. When completing the shift down, depress the accelerator pedal at the same time and thrust the bucket into the load.

Stockpile 3. When the material is in a stockpile, keep the cutting edge of the bucket horizontal when loading blasted rock, have the bucket tilting slightly down. *

Be careful not to get blasted rock under the bucket. This will make the front tires come off the ground and slip.

*

Try to keep the load in the center of the bucket; if the load is on one side of the bucket, the load will be unbalanced.

Blasted rock

2-64

OPERATION 4. At the same time as thrusting the bucket into the

material, raise the lift arm to prevent the bucket from going in too far. By raising the lift arm, ample traction will be produced by the front tires.

5. Check that there is enough material loaded into the bucket, then operate the bucket control lever to tilt the bucket and load the bucket fully. *

If the bucket edge is moved up and down while pushing in the bucket and digging, the front tires will come off the ground and this will cause the tires to slip.

6. If there is too much material loaded in the bucket, dump and tilt the bucket quickly to remove the excessive load.

This prevents spillage of the load during hauling.

0

When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the machine forward. Always be careful not to load the bucket on one side and cause an unbalanced load.

*

This operation should be carried out in 1st gear.

1. Set the edge of the bucket facing slightly down.

2-65

OPERATION 2. Drive the machine forward and operate the lift arm control lever forward to cut a thin layer of the surface each time when excavating the soil.

3. Operate the lift arm control lever slightly up and down to reduce the resistance when driving the machine forward. *

When digging with the bucket, avoid imposing the digging force onto only one side of the bucket.

A

WARNING! Never dig or scoop when the machine is articulated.

Precautions when scooping

up materials.

When scooping up materials, be careful not to let the counterweight at the rear touch the ground.

*

Do not allow tires slipping to occur during operation. Tire slippage shortens tire’s life.

LEVELING 1. Scoop soil into the bucket. Move the machine backward while spreading soil from the bucket little by little.

2. Go over the spread soil with the bucket teeth touching the ground and level the ground by back-dragging.

3. Scoop some more soil into the bucket, put the lift arm in float, level the bucket at ground level, and smooth the ground by moving backward. *

Always move the leveling operations.

A 2-66

machine

backward

during

WARNING! If leveling by forward travel can not be avoided, do not dump the bucket beyond 20�. This will prevent quick wear and damage of the work equipment and frame.

OPERATION

LOAD AND CARRY OPERATIONS Load and carry operation is a series of processes (scooping - carrying - loading to a hopper or glory hole) carried out by the wheel loader. *

Always maintain the road in good condition.

A

WARNING! Lower the bucket to bring down the center of gravity when carrying material.

LOADING Select and proceed effective operation which avails less turning and the shortest hauling distance according to ground conditions.

Cross Drive Loading When a wheel loader is operated, the digging should be made at a right angle toward accumulated soil.

When the scooping is completed, the machine should be traveled backwards as it is. Then, bring the truck between the accumulated soil and the wheel loader for the purpose of loading upon the dump truck.

A A

WARNING! Provide a flat road free of rocks and hollows. When the boom is raised with the bucket loaded, do not make quick turns or quick braking because it is very dangerous.

WARNING! Do not load the bucket by thrusting into a pile of soil or gravel at high speed because it is dangerous.

Ll7CZO22

V-Shape Loading Stop the truck with the angle of about 60� toward the scooping direction of the wheel loader. After scooping the soil, back the wheel loader in such a way that it makes a right angle to the truck. The loading on the truck is made by the wheel loader going forward.

The smaller the turning angle, the higher the efficiency. However, turning of 90� can be made if necessary.

L17CZO23

2-67

OPERATION PARKING

A

WARNING! Never leave the machine with the engine running or the bucket raised.

When parking the machine, stop the engine, lower the bucket to the ground, place the transmission in neutral (N), apply the parking brake, turn off the electrical starting switch, and remove the key.

MACHINE

A

WARNING! Before starting the engine or when the machine is standing with the engine running: Place the transmission in neutral (N), apply the parking brake, and lower all raised work equipment.

Park machine in an area free of grease and fuel puddles which cause tire deterioration.

A

A

2-68

WARNING! Park the machine in a nontraffic area. If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and warning signals.

Also provide advance warning signals in the traffic lane for approaching traffic.

WARNING! Avoid parking on a slop because unexpected machine movement may occur. If necessary to park on a slope, park at a right angle to the slope and block the tires.

Lower hydraulically supported equipment to the ground to avoid unexpected movement and damage possibilities.

Park on level ground to obtain lubricant and fuel level checks.

A

accurate

coolant,

WARNING! Always lock up the machine, including any anti-vandalism attachment, when leaving it unattended.

OPERATION ADJUSTMENT The boom so that it height (lift positioner

OF WORK EQUIPMENT

kickout makes it possible to set the bucket automatically stops at the desired lifting arm higher than horizontal) and the bucket makes it possible to set the bucket so that

it automatically stops at the desired digging angle.

The setting can be adjusted to match the working conditions.

ADJUSTING BOOM KICKOUT 1.

Raise the bucket to the desired height, set the lift arm control lever at HOLD and lock the lever in position. Then stop the engine and adjust as follows.

2.

Loosen two bolts (1) and adjust plate (2) so that the bottom edge is in line with the center of the sensing surface of proximity switch (3). Then tighten the bolts to hold the plate in position.

3.

Loosen two nuts (4) to make a clearance of 3 to 5 mm between plate (2) and the sensing surface of proximity switch (3). Then tighten the nuts to hold in position.

*

Tightening

4.

After adjusting, start the engine and operate the lift arm control lever. Check that the lever is automatically returned to HOLD when the bucket reaches the desired height.

torque:

1.75 ? 0.25 kgm

2-69

OPERATION ADJUSTING BUCKET POSITIONER 1.

Lower the bucket to the ground and adjust the bucket to the desired digging angle. Set the bucket control lever at HOLD, stop the engine and adjust as follows.

2.

Loosen two bolts (5) and adjust mounting bracket (8) of the proximity switch so that the rear tip of angle (6) is in line with the center of the sensing surface of proximity switch (7). Then tighten the bolts to hold the bracket in position.

3.

Loosen two nuts (9) to make a clearance of 3 to 5 mm between angle (6) and the sensing surface of proximity switch (7). Then tighten the nuts to hold in-position.

*

Tightening

torque:

1.75 -co.25 kgm

4.

After adjusting, start the engine and raise the lift arm. Operate the bucket control lever to the DUMP position, then operate it to the TILT position and check that the bucket control lever is automatically returned to HOLD when the bucket reaches the desired angle.

BUCKET LEVEL INDICATOR Surface (a) at the top rear of the bucket is the level indicator, so the bucket angle can be checked during operations.

Surface (a) 90� to cutting edge.

2-70

L08BV019

OPERATION HANDLING TIRES PRECAUTIONS WHEN HANDLING TIRES If the following defects are found in tires, for safety reasons the tire should be replaced with a new tire.

Bead wire is broken or bent, or the tire is greatly deformed.

Wear is excessive and the carcass ply (excluding breaker) is exposed for more than l/4 of the circumference.

Damage to the carcass exceeds l/3 width.

of the tire 5

L15AR021 J

Tire layers are separated.

1 = Sidewalls 4 = Carcass

Radial cracks reach the carcass.

Deformation or damage unsuitable for use.

which

2 = Tread 3 = Breakers 5 = Beads

makes the tire

PRECAUTIONS WHEN DRIVING MACHINE When the machine travels at high speed for a long distance, the tires become extremely hot. This causes early wear of the tires, so it should be avoided as far as possible. If the machine must be driven for a long distance, take the following precautions. l

0

* 0

Follow the regulations and drive carefully.

Tire pressure: Speed :

2.8 kg/cm2 17 km/h

l

Check the tire pressure before starting, when the tire is cool.

0

After traveling for 1 hour, stop for 30 minutes.

Check the tires and other parts for damage; also check the oil and coolant levels.

0

Always travel with the bucket empty.

0

Never put calcium chloride or dry ballast in the tires when traveling.

related to this machine,

The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface. Contact your distributor or tire dealer for information.

The following is a guide to suitable tire pressures and speeds when traveling on a paved surface with standard tires.

TIRE PRESSURE Measure the tire pressure before starting operations, when the tires are cool.

tire may be cut or may burst under shock. Therefore adjust the inflation pressure to the values in the following table.

If the inflation pressure is too low, it causes overload on the tires; if the inflation pressure is too high, the

2-71

OPERATION

Tire size (pattern)

inflation pressure (kg cm’)

Ply rating

Digging

Stockpile 20.5 - 25 (L3 Rock)

1.9

When shipped from factory

Normal road

Soft ground (sandy ground)

- 3.3

2.1 - 3.5

1.9-3.3

20.5 - 25 (L2 Traction)

Front tire: 3.0 Rear tire: 2.8

12 17.5 - 25 (L3 Rock)

2.9

2.5 - 3.5

- 3.5

17.5 - 25 (L2 Traction)

These recommendations apply to the standard machine with the rated payload. The addition of optional equipment or a change of operation conditions may require an adjustment to the recommended pressure.

*

When checking the tire pressure, check also for small cracks and damage, and for wire or small pieces of metal which may cause punctures.

Check also for abnormal wear.

Stockpile operations on soft ground: Average pressure in air pressure chart.

*

Operations on sand (operations not using much digging force): Low end of range in air pressure chart.

Operating costs can be reduced and tire life increased by keeping the operating area in good condition and free from fallen rocks.

*

Deflection ratio (deflection/free

0

For operations on normal road surfaces, rock digging operations: High end of range in air pressure chart.

0

0

If the deflection of the tire is excessive, raise the inflation pressure within the limits given in the table to give a suitable deflection (see deflection ratio).

Stockpile operations mean the loading of sand and other loose materials.

*

height)

H-h =

x 100 H

H: Free height h: Height when loaded

As a guide for visual checks, the deflection ratio (deflection/free height) of the front tire should be as follows.

Normal loading and carrying operations horizontal): approx. 1525%

(lift arm h

Digging operations approx. 25 - 35%

(rear wheels off ground):

Li 5AR017

2-72

OPERATION

TOWING TOWING This machine must not emergencies. When towing following precautions.

A

be towed except in the machine, take the

If there is a failure in the WARNING! brake line, the brakes cannot be used, so be extremely careful when towing.

WHEN ENGINE CAN BE USED l

THE MACHINE WHEN ENGINE CANNOT BE USED l

No lubrication oil flows in the transmission, so disconnect the front and rear drive shafts before moving the machine.

l

The steering cannot be used, so disconnect steering cylinder and steering linkage.

f

The machine should be towed only to the nearest place for inspection and maintenance. Do not tow the machine for long distances.

the

Always keep the engine running when towing the machine, so that the steering and braking can be used.

TRANSPORTATION When transporting the machine, observe the various road rules, road transportation vehicle limit ordinances, etc. It is a good idea to obtain a special platform for loading and unloading the machine. When it is unavoidably necessary to use a gangplank, however, at the very least observe the following for the sake of safety.

1.

Properly apply the brakes on the trailer and insert blocks beneath the tires to ensure that it does not move. Then fix the gangplank in line with the centers of the trailer and the machine.

A

WARNING! Do not on any account change the direction of the machine while it is on the gangplank. To change the direction of the machine, first take it down from the gangplank.

Correctly load the machine onto the specified part of the trailer.

Lower the bucket and lock each control using the safety lock.

lever

Lock the front and rear frames with the safety bar. *

Make sure the gangplank has sufficient width, length and thickness to enable the machine to be safety loaded and unloaded.

If the gangplank sags appreciably, it with blocks, etc.

reinforce

When transporting the machine, place blocks underneath the front and rear wheels to prevent the machine from moving about. Also, hold it down with chains or wire ropes. *

2.

Determine the direction of the gangplank, then slowly load or unload the machine. *

A

When transmission cut-off switch is put in OFF, the left brake pedal and accelerator pedal are operated at the same time.

A

Determine the route for transporting the machine by taking into account the width, height and weight of the machine.

WARNING! When loading the machine, park the trailer on flat roadbed. Keep a fairly long distance between the road shoulder and the machine.

WARNING! Remove the mud from the undercarriage to prevent the machine from slipping to the side on slopes.

2-73

OPERATION COLD WEATHER OPERATION PREPARATION

FOR LOW TEMPERATURE BAlTERY

If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.

0

As ambient temperature drops, battery capacity will drop, and electrolyte may sometimes freeze if battery charge is low. Maintain battery at a charge level of approx. 100% and insulate it against cold temperature so that machine can be readily started the next morning.

f

When electrolyte level is low, add distilled water in the morning before work instead of after the day’s work. This is to prevent fluid from freezing at night.

FUEL AND LUBRICANTS Change to fuel and oil with components.

low viscosity

for all

For details of the specified viscosity, see the TABLE OF FUEL, COOLANT AND LUBRICANTS.

To avoid gas explosions, do WARNING! not bring fire or sparks near the battery.

COOLANT Use antifreeze during all seasons to protect the cooling system from corrosion as well as freezing damage.

If the electrolyte gets on your WARNING! skin or clothes, immediately wash with plenty of clean water.

A mixture of 50% water and 50% ethylene-glycol base antifreeze is required for operation of the engine in temperature environments above -37°C. A mixture of 40% water and 60% antifreeze is recommended for temepratures below -37” C. *

-1

20°C 100% 90% 80% 75%

1.28 1.26 1.24 1.23

CAUTIONS

0°C

-10°C

-20°C

-30°C

1.29 1.27 1.25 1.24

1.30 1.28 1.26 1.25

1.31 1.29 1.27 1.26

1.32 1.30 1.28 1.27

AFTER

COMPLETION

1. Mud and water on the machine body should be

completely removed. Park the machine on concrete or hard ground. If this is impossible, park the machine on wooden boards. This will prevent the accessories from freezing to the ground thereby preventing machine movement the next morning.

2.

Particular attention should be given to water drops collected on the surface of the hydraulic cylinder piston rods. Such droplets must be fully

2-74

Measure specific gravity of fluid and obtain rate of charge from the following conversion table:

OF WORK

wiped off because if water is frozen to the rod when the cylinder is utilized, the cylinder oil seals may be damaged.

3.

Drain water collected in fuel system so that such water may be frozen at night.

4.

As battery capacity drops at low ambient temperature, cover the battery or remove it from the machine to be kept warm at night.

OPERATION AFTER

COLD WEATHER

When weather becomes warm, perform the following without fail: l

Replace lubricating oils for various units with the ones specified for warm-weather use.

LONG TERM STORAGE BEFORE To place period of to insure minimum

the machine in storage for an extended time, the following measures must be taken that it can be returned to operation with a of service.

STORAGE 0

Disconnect the negative terminals of the batteries and cover the batteries or remove them from the machine and store them separately.

0

When the ambient temperature is anticipated to drop below 0�, always add antifreeze in the cooling water.

After every part is washed and dried, the machine shall be housed in a dry building. Never leave it outdoors.

0 If it is unavoidable to leave it outdoors, park the machine on flat ground and cover it with canvas, etc.

Set each control lever to neutral or hold position, lock them and apply the parking brake.

0

Open the air tank drain valves to completely drain the tanks. After draining, close the drain valves.

Completely fill the fuel tank, lubricate and change oil before storage.

*

If the engine will be out of service longer than six (6) months, take special precautions to prevent rust. Contact the nearest Distributer for

l

Operate the engine and move the machine for a short distance once a month so the new oil film will be coated over movable parts and component surfaces.

l

Before operating the work equipment, wipe off the grease on the hydraulic cylinder piston rods.

Apply a thin coat of grease to the metal surfaces of the hydraulic cylinder piston rods and splined shafts.

A

If it is unavoidably necessary to carry out rust-preventive operation while the machine is indoors, open up doors and windows to improve ventilation and prevent the gas poisoning.

AFTER NOTICE:

Carry

If the machine is stored without out the monthly rust carrying prevention operation, request your distributor for service.

STORAGE

OPERATION

HANDLING OF BAlTERY PRECAUTIONS

FOR CHARGING

1.

Before charging, disconnect the cable from the negative (-) terminal of the battery. Otherwise, an unusually high voltage will damage the alternator.

2.

While charging the battery, remove all battery caps for satisfactory ventilation.

A

5.

WARNING! To avoid gas explosions, do not bring fire or sparks near the battery.

6.

If the

electrolyte

WARNING!

temperature

a

exceeds

touches

45°C

connected

STARTING starting follows:

A

engine

booster

l

WITH do

WARNING! Be sure to follow all related safety precautions listed in Section 1.

BEFORE CONNECTING

BOOSTER CABLES

1.

The size of the booster cable and clamp should be suitable for the battery size.

2.

Check booster cables and clamps for damage or corrosion.

2-76

BATTERY

CABLES 3.

sure

the

and

are

4.

Keep the starting switch in the “OFF” position.

5.

The battery of the normal machine must be the same capacity as that of the engine to be started.

OPERATION

CONNECTING

BOOSTER CABLES

Connect the booster cables in the following

A A

manner.

WARNING! When connecting the cables, never contact the positive (+) and negative (-) terminals.

WARNING! Make sure that the booster cable connections are correct. Connect the booster cable to the enaine block as far as possible from the battery.

1.

Connect one clamp of booster cable (A) to the positive (+) battery terminal of the engine to be started.

2.

Connect the opposite clamp of booster cable (A) to the positive (+) battery terminal of the normal machine.

3.

Connect one clamp of booster cable (B) to the negative (-) battery terminal of the normal machine.

4.

Connect the other clamp of booster cable (B) to the engine block of the problem machine.

*

Make sure the cable clamps are firmly connected to the battery terminals.

“I” = Engine block of problem machine “II” = Booster batteries “Ill” = Batteries of problem machine

STARTING ENGINE 1.

Start the engine of the normal machine and run the engine above low idle speed.

2.

Start the engine of the problem machine outlined under “STARTING ENGINE”.

DISCONNECTING

as

BOOSTER CABLES

After the engine has started, disconnect the booster cables in the reverse order in which they were connected.

“I” = Engine block of problem machine “II” = Booster batteries “Ill” = Batteries of problem machine

Disconnect the clamp of booster cable (B) from the engine block of the problem machine.

Disconnect the other clamp of booster cable (B) from the negative (-) battery terminal of the normal machine.

Disconnect the clamp of booster cable (A) from the positive (+) battery terminal of the normal machine.

Disconnect the other clamp of booster cable (A) from the positive (+) battery terminal of the problem machine.

2-77

OPERATION TROUBLESHOOTING This guide is not intended to cover all conditions, however many of the more common possibilities are listed.

0

In cases of abnormalities or causes which are not listed below, contact your distributor.

ELECTRICAL SYSTEM Lamp does not glow brightly even when engine runs at high speed.

Lamp flickers while engine runs.

Check for loose terminals and open-circuit wiring. l l Adjust belt tension.

Charge monitor does not go out even when engine runs at high speed.

Repair or place the alternator. l 0 Inspect and repair wiring.

Unusual noise is emitted from the alternator.

Repair or replace the alternator.

l

Cranking motor does not turn when starting switch is turned on.

Inspect and repair the wiring. l 0 Charge the batteries.

The pinion of the cranking motor keeps going in and out.

0 Charge the batteries.

Cranking motor turns the engine sluggishly.

0 Charge the batteries.

Replace the cranking motor. l

2-78

The cranking motor disengages before the engine starts up l Check and repair the wiring. l Charge the batteries.

The engine oil pressure monitor does not light up when engine is stationary and when the starting switch is in ON position. l Replace the monitor. l Replace the monitor sensor. l Inspect and repair the wiring.

Charge monitor does not light up when the engine is stationary and when the starting switch is in ON position. l Replace the monitor. l Inspect and repair the wiring.

OPERATION

ENGINE Engine cranks but will not start (no smoke from exhaust). l Add fuel. l Adjust cable to shut down lever. l Check and blow fuel lines. l Check and replace lift pump. l Change fuel filters. l Check and repair injection pump.

The engine does not start when the cranking motor is turned over. l Add fuel. l Repair where air is leaking into fuel system. l Replace the injection pump or the nozzle. l Check engine valve clearance. l Check engine compression pressure. l Refer to section for ELECTRICAL SYSTEM.

Engine hard to start or will not start (smoke from exhaust). l Check battery, starting motor and wiring. l Drain fuel and clean fuel system. l Check and replace air cleaner filter. l Bleed fuel system. l Check injection pump timing. l Reset valve lash.

Exhaust gas is white or blue. l Adjust to specified oil quantity. l Replace with specified fuel.

The engine oil pressure monitor flashes when engine speed is raised after completion of warm-up. l Add the oil to the specified level. l Replace the oil filters. l Check oil leakage from the pipe or the joint. l Replace the monitor.

Steam is emitted from the top of the radiator at the pressure valve.

The engine coolant temperature monitor flashes. l Supply the coolant and check for leakage. l Adjust fan belt tension. l Clean and flush inside of cooling system. l Clean or repair radiator core fins. l Replace engine thermostat. l Tighten the radiator cap firmly or replace the cap if it has a faulty gasket. l Replace the monitor.

Exhaust gas occasionally turns black. l Clean or replace the air cleaner element. l Replace the nozzle. l Check engine compression pressure. l Clean and replace turbocharger.

Combustion noise occasionally breathing sound. l Replace the nozzle.

changes

to

Unusual combustion noise or mechanical noise. l Replace with specified fuel. l Check over-heating. l Replace the muffler. l Adjust valve clearance.

2-79

OPERATION CHASSIS TRANSMISSION

PARKING BRAKE

Engine is running but machine will not move.

Release parking brake. l Put directional lever in position properly. l Add oil to transmission case to the specified level.

Brake does not work properly.

0 Adjust linkage.

0 Clean brake pad. l Adjust or replace brake pad.

l

Even at full throttle, machine moves slowly and lacks power. l Add oil to transmission case to the specified level. l Disassemble transmission strainer and clean.

Oil overheats. l Add oil to transmission case to the specified level or drain oil.

0 Use a suitable gear speed. l Reduce time using torque converter at stall speed. l Check engine.

Abnormal noise is produced. l Add oil to transmission case to the specified level.

DRIVE AXLES Abnormal noise is produced. l Add oil to axle housing up to proper level.

STEERING Steering wheel is heavy.

0 Adjust steering gear. l Check linkage, replace parts.

EQUIPMENT HYDRAULIC SYSTEM Bucket lacks lifting power.

Bucket lifting speed is slow. l Add oil. l Replace filter in hydraulic tank.

Many bubbles form in oil. l Replace with specified oil. l Add oil.

0 Bleed air from oil line.

Oil pressure is too low. l Add oil and bleed air.

WHEEL BRAKES Brakes do not work when pedal is depressed. l Replace discs. l Add brake oil to the specified level. l Bleed air from brake system.

Brake drags or stays applied. l Clean exhaust hole of treadle valve. l Clean breather of power cluster. l Check and repair slack adjuster.

Brake slips. l Replace discs.

2-80

Cylinder vibrates l Add oil.

when operating.

SECTION

3

MAINTENANCE

WARNING SAFETY

! REFER

TO

PRECAUTIONS

AND IN

READ SECTION

ALL 1.

3-1

PERIODIC MAINTENANCE Proper lubrication maintenance and assure trouble-free operation and long machine life. Time and money spent for scheduled periodic maintenance will be amply compensated by prolonged machine operation and reduced operating cost.

however, it is recommended to rearrange all of them into units of days, weeks and months, to make the maintenance schedule more convenient. Under rough jobsite or operating conditions, it is necessary to somewhat shorten the maintenance intervals stated in this manual.

All hourly figures given in the following descriptions are based on service meter readings. In practice,

MAINTENANCE GUIDELINES Perform maintenance work on a hard, flat surface.

Use genuine parts specified replacement parts.

in the Parts Book as

Obey precautions: During operation, always obey the precautions on the safety product graphics located on the machine.

Use clean oil and grease. Also, keep containers of the oil and grease clean. Keep foreign materials away from oil and grease.

Welding instructions: l Turn off the engine starting switch. l Do not apply more than 200 V continuously.

0 Connect grounding cable within 1 m (3.3 ft) from the area to be welded. l Avoid seals or bearings from being between the area to be welded and the position of the grounding point.

Always keep the machine clean. This makes is easier to find parts causing problems. Keep in particular grease fittings, breathers and oil level gauges clean and avoid foreign matters from getting in them.

Fire prevention: Use a nonflammable cleaner or light oil for cleaning parts. Keep flame or cigarette light away from cleaning fluid.

Be careful of hot coolant and oil: Draining hot oils and coolants and removing their filters immediately after the engine stops are hazardous. Allow the engine to cool. If the oil has to be drained when it is cold, warm up the oil to a suitable temperature (approx. 20”-4O”C [68’104”F]) before draining it.

Clamping faces: When O-rings or gaskets are removed, clean the clamping faces and replace the O-rings and gaskets with new ones. Be sure to properly fit the O-rings and gaskets when assembling.

Use genuine oils and grease. Choose oils and grease with proper viscosities specified for the ambient temperature.

Check for foreign materials in drained oil: After oil is changed or filters are replaced, check the oil and filters for metallic particles and foreign materials. If large quantities of metallic particles or foreign materials are found, consult your distributor.

Fuel strainer: Do not remove the fuel strainer while fueling.

Oil changes: Check or change oils in the places where dust is scarce to keep foreign materials away from oils.

Warning tag: Attach the warning tag to the starting switch or other appropriate control lever to avoid someone who is not aware of the circumstances from starting the engine.

3-2

Objects in your pockets: Keep your pockets free of loose objects which can fall out and drop into the machinery; especially when you work on the machinery while bending over it.

Cleaning machine: l Do not direct a high-pressure jet directly at the radiator. l Do not splash water on the electrical components.

Pre- and post-work checks: Before starting work in mud, rain, snow or at the seashore, check plugs and drain valves for tightness. Wash the machine immediately after the work to protect components from rusting. Lubricate components more frequently than usual. Be sure to

MAINTENANCE

lubricate work equipment submerged in water.

pins

daily

if they

are

l

Dusty worksites: When working at dusty worksites, do as follows: l Check the air cleaner for clogging more frequently. Clean the air cleaner at shorter intervals than specified. l Clean the radiator core frequently to avoid clogging. l Replace the fuel filter(s) frequently.

Clean electrical components, especially the cranking motor and alternator, to avoid accumulation of dust.

Avoid mixing oils: Never mix oils of different brands. If you have only oil which is a different brand from the one that is used in the machine, do not add it but replace all the oil.

OUTLINES OF SERVICE LUBRICATION l

Use genuine oils and grease. Choose oils and grease with proper viscosities specified for the ambient temperature.

l

When changing or adding different type of oil.

WHEN l

SHIPPED Unless otherwise specified, the oils, grease, fuel and coolant used at the time of shipment from the factory are as shown in the table below.

oil, do not use a

LUBRICANT

COMPARTMENT

Engine oil SAE 15W-40 API classification

Engine

CE

Engine oil SAE 30W API classification

CE

Service brakes

Engine oil SAE 1OW API classification

CE

Hydraulic system

Engine oil SAE 1OW API classification

CE

Drive axles - Front & rear

Axle oil - See NOTE

Lubrication fittings

No. 2 multi-purpose num disulfide

Fuel tank

Diesel fuel ASTM D975 Grade No. 2-D

Cooling system

Coolant mixture of water, antifreeze, & supplemental coolant additives

Torque converter, Transmission, cooler

Transfer case & Oil

NOTE: For axle oil, one of the following SHELL: CALTEX: CHEVRON: TEXACO: MOBIL:

lithium grease with 3% molybde-

oils was used:

DONAX lT or TD RPM TRACTOR HYDRAULIC FLUID TRACTOR HYDRAULIC FLUID TDH OIL MOBIL AND SUPER UNIVERSAL

3-3

MAINTENANCE

RELATING TO ENGINE ENGINE OIL

DIESEL FUEL

l

Engine oil is critical because it lubricates engine, the heart of the machine.

the

0

Always use the fuel specified for the engine. Fuels other than the specifications can damage the engine or reduce the engine output.

0

Main services relating to engine oil are: 1) daily check of oil level, 2) check for contamination and 3) periodic replacement.

0

Always fill the fuel tank at the end of the day’s operation.

0

When adding fuel, be careful not to let any water on top of the drum or at the bottom of the drum get into the fuel.

0

After the machine has run out of fuel or after the fuel filter has been replaced, bleed the air from the fuel line.

COOLANT Coolant is used to cool the engine and to keep it in good working condition.

Check coolant level in the radiator maintain it at the proper level.

daily and

For coolant recommendations/specifications, refer to “COOLANT” under “LUBRICANTS, FUEL AND COOLANT”.

RELATING TO HYDRAULIC SYSTEM l

Use extreme caution when servicing the hydraulic system, because oil in the system soon after the operation is very hot. Also, high pressure is applied in the system not only during but also after the operation.

l

Services relating to the hydraulic system are: 1) weekly check of oil level, 2) periodic filter replacement and 3) periodic oil replacement.

l

Always bleed the air from the circuit after replacing the filter or changing the hydraulic oil.

l

When a item, such as a hose, in the line is disconnected, check O-rings for damage and replace them if necessary.

l

If a hydraulic component has been removed or any hydraulic line has been disconnected or removed, bleed the air from the hydraulic tank and system after completion of assembly. Bleed the air from the tank and system as described “HYDRAULIC TANK” and/or “PPC under (PROPORTIONAL PRESSURE CONTROL) CIRCUIT” in the section.

RELATING TO ELECTRICAL SYSTEM l

l

If the wiring gets wet or the insulation is damaged, the electrical system leaks and this could result in hazardous malfunction of the machine.

Services relating to the electrical system are: 1) check fan belt tension, 2) check for damage or wear of the fan belt and 3) check the battery electrolyte level.

l

Never remove or disassemble any components installed on the machine.

l

Never install any electrical components other than

3-4

electrical

those specified by Komatsu Dresser Company. l

Be careful to keep the electrical system free of water when washing the machine or when it rains.

l

When working on the seashore, carefully clean the electrical system to prevent corrosion.

l

Never connect any optional power source to the fuse, starting switch, battery relay, etc.

MAINTENANCE RELATING TO LUBRICATION Lubrication is to help smooth operation of the machine and work equipment. It prevents the machinery from being subjected to excessive load and from getting caught or generating noise.

There are two lubricating methods; using oil and using grease.

overhaul purpose, and no greasing is required for them.

0

Always use only the lubricants specified “LUBRICANTS, FUEL AND COOLANT�.

under

After adding new grease, wipe off old grease that was forced out, especially on rotating parts that could be worn by sand and dirt adhering to them.

Services relating to lubrication are: 1) check of oil levels, 2) periodic changing of oil and 3) adding grease for proper lubrication.

Maintain oil at the proper level. Both too high and too low oil levels are not good for the machine.

The machine has grease fiiings in various places.

Some of the fittings may not be mentioned in this manual. These fittings are equipped for the

BLEEDING AIR tank to bleed the air. After bleeding the air, tighten the air bleed plug (1).

BLEEDING AIR FROM HYDRAULIC TANK The hydraulic tank and system should be bleed free of air after the following: l

Replacing the hydraulic oil and filter elements or cleaning the oil strainer.

l

Removing a hydraulic component disconnecting hydraulic piping.

or

After reassembly, bleed the air from the hydraulic tank and system as follows: 1.

Check and if necessary refill the hydraulic tank with oil up to the specified oil level of the sight gauge.

NOTICE:

a

Check the hvdraulic tank oil level and refill with oil frequently when bleeding the system.

WARNING! At first, if the engine is operated at high speed or if the hydraulic cylinder is moved to the end of its stroke, the air in the cylinder may damage the cylinder piston packing, etc.

Run the engine at low idle. One at a time, operate the hydraulic steering, bucket and lift arm cylinders four (4) to five (5) times, stopping 100 mm (3.9 in) from the end of its full stroke.

Next, operate each hydraulic cylinder three (3) to four (4) times, to the end of its stroke, then stop the engine.

c LlOBVOfir

5.

Recheck the hydraulic tank oil level and add oil as necessary.

6.

Start the engine, increase the engine speed and repeat Steps 3 and 4 to bleed the air until no more bubbles come out from the bleed plug ports.

7.

After bleeding the air, tighten the air bleed plug (1).

*

Tightening torque of bleed plug: 1.I5 2 0.15 kgm (8.3 ? 1.0 Ibf ft / 11.3 2 1.4 Nom)

8.

Recheck the oil level in the hydraulic tank and add oil as necessary. After adding oil, tighten the oil filler cap securely.

Loosen the air bleed plug (1) on the hydraulic

3-5

MAINTENANCE BLEEDING AIR FROM HYDRAULIC CIRCUIT

THE

WHEEL

BRAKE

The wheel brake hydraulic circuit should be bleed free of air after the following: l

Removing a brake hydraulic component disconnecting brake hydraulic piping.

or

After reassembly, bleed the air from within the brake hydraulic circuit as follows:

A 1.

WARNING! When bleeding air from within the brake hydraulic circuit, always place blocks or chocks under the tires to prevent the machine from moving.

Check and if necessary refill the brake oil tank with oil up to the specified oil level of the sight gauge.

NOTICE: Check the brake oil level and refill with oil frequently when bleeding the system.

2.

Run the engine at low idle. Remove the protective cap of air bleed plug (A).

3.

Depress and hold the brake pedal and loosen bleed plug (A) about 3/4 of a turn at one of wheel brakes to bleed the air. After bleeding air, tighten the air bleed plug and release brake pedal.

4.

Repeat the previous step to bleed the air until air bubbles stop coming out from the bleed plug port. After bleeding the air, tighten air bleed plug (A) and install the protective cap.

5.

Recheck the brake oil level and add oil as necessary.

6.

Repeat Steps 2 thru 5 to bleed the air at the remaining three (3) brakes.

7.

Stop the engine.

8.

Recheck the oil level in the brake oil tank and add oil as necessary. After adding oil, tighten the oil filler cap securely.

*

For further details, contact your distributor.

3-6

air the the the

MAINTENANCE

BLEEDING AIR FROM FUEL SYSTEM Manual bleeding will be required if: l

The fuel filter is not filled prior to installation.

0

Injection pump is replaced.

l

High pressure fuel lines are replaced.

Venting the low pressure lines and fuel filter 1.

Loosen bleed screw (1).

2.

Operate hand lever (2) until the fuel flowing from the fitting is free of air.

Tighten bleed screw (1) to 0.82 kgm.

Venting at the injection pump 1.

Air can be vented from the injection pump through the fuel drain manifold line by operating the starting motor.

*

When using the starting motor to vent the system, do not engage it for more than 30 seconds at a time: wait two minutes between engagements.

A

WARNING! It is necessary to put the engine in the “RUN� position. Because the engine may start, be sure to follow all the safety precautions. Use the normal engine starting procedure.

A = OFF

B = ON

C = START

3-7

MAINTENANCE Venting the high pressure lines *

A 1.

A A 2.

When using the starting motor to vent the system, do not engage it for more than 30 seconds at a time: wait two minutes between engagements.

WARNING! It is necessary to put the engine in the “RUN� position. Because the engine may start, be sure to follow all the safety precautions. Use the normal engine starting procedure.

Loosen fittings (f) at the injectors, and crank the engine to allow entrapped air to bleed from the lines. Tighten the fittings.

WARNING! High pressure penetration of the skin.

could

cause

I

WARNING! Do not bleed a hot engine as this could cause the fuel to spill onto a hot exhaust manifold creating a danger of fire.

Start the engine and vent one line at a time until the engine runs smoothly (at 700 rpm).

I llAJ029 A = OFF

3-8

4

B = ON

C = START

MAINTENANCE WEAR PARTS REPLACEMENT The wear parts should be changed correctly in order to use the machine economically.

Wear parts such as filters, filter elements, cutting edge, etc. are to be replaced at the time of scheduled maintenance or before their functional and serviceable limits.

Part Description

Use genuine parts specified replacement parts.

Replacement

Quantity

Engine oil filter

2

Every 250 hours service

Fuel filter

1

Every 800 hours service

Transmission oil filter element

1

Every !500 hours service

Hydraulic tank oil filter element

1

Every 2COOhours service

Hvdraulic tank breather element

1

Everv 2800 hours service

Air cleaner element

2

When required

Engine fan drive belt

1

When required

Bucket teeth - if equipped

8

When required

Bucket bolt-on cutting edge

3

When required

in the Parts Book as

Interval

PERIODICAL PART REPLACEMENT The users of the machine should carry out periodical maintenance in order to ensure proper and safe operation. The parts, listed below, should be replaced periodically so that the highest safety standard can be maintained.

These parts with the passage of time may have a tendency to deteriorate in quality and to wear or deform. These parts must be replaced with new ones after a predetermined replacement interval even though there is no apparent abnormality.

If any abnormality should be found, these parts must be replaced or repaired even before the predetermined period expires.

Periodical part replacement cost does not imply reimbursement under the manufacture’s warranty policy. Refer to the warranty manual for further details.

Replacement interval

Part description Brake hoses

Every year

Piston and packing of service brake master cylinder

Every year

Packings, seals, O-ring of steering cylinders

Every 2 years

Rubber hoses for steering cylinders

Every 2 years

Fuel hoses

Every 2 years

Remarks

Replace with repair kit

3-9

MAINTENANCE LUBRICANTS,

FUEL AND COOLANT

PROPER RESERVOIR

FLUID TYPE

-22 -30

SELECTION

TABLE

AMBIENT TEMPERATURE 14 32 50 68 86 -10 0 10 20 30

-4 -20

CAPACITY 104 4.o

122°F 50°C

Specified

Refill

16.4 P 4.3 gal

14.3 e 3.8 gal

’

35.0 e 9.2 gal

25.0 P 6.6 gal

1

98.0 e 25.9 gal

63.0 P 16.6 gal

i e

1.o qt.

1e 1.0 qt

16 e 4.2 gal each

16 e 4.2 gal each

: ‘,. :‘?SAE’y5W40

Engine with filters

Engine oil See NOTE 1

.:sn~paw-30 .,.:I $~n~~c.

.. .;

.Y:’:‘.. .. : ‘.,’ Y,“’

Torque converter, Transmission, Transfer case & Oil cooler Hydraulic system

$AE . . . . ;ti$o

SAE 1OW

Engine oil See NOTE 2

Service brakes

1 SAE 1OW

I I

[.

:I;:.:SAE..3(W

SAE SW-20

I

SAE.:lO)V

Drive axles Front & rear

Axle oil

All lubrication fittings

Grease

See NOTE 4

Fill as instructed

--

Fuel tank

Diesel fuel

See NOTE 5

170.0 e 44.9 gal

--

Cooling system

Coolant

See NOTE 6

38.0 P 10.0 gal

--

API: ASTM: SAE:

See NOTE 3

American Petroleum Institute American Society of Testing and Material Society of Automotive Engineers

Specified capacity: Total amount of oil including oil for components and oil in piping.

Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

3-10

MAINTENANCE NOTES: 1. ENGINE OIL

Normal Operation Oil performance recommendations

are as follows:

The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability.

SAE 15W-40 multi-viscosity oil meeting the American Petroleum Institute (API) performance classification of CE or CF4 is recommended.

NOTE: CD or CD/SF oils may be used in areas where CE or CF-4 oil is not yet available.

Oil viscosity recommendations

A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control. The sulfated ash must not exceed 1.65 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage and lead to excessive oil consumption.

The API service symbol displays the following information. The upper half of the symbol displays the appropriate oil categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the SAE oil viscosity grade.

are as follows:

The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine cranking in cold temperatures while maintaining lubrication at high operating temperatures.

While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previous chart for oil viscosity recommendations for extreme climates.

Limited use of low viscosity oils, such as SAE low-30 may be used for easier starting and oil flow at ambient providing sufficient temperatures below -5°C (+23”F).

However, continuous use of low viscosity oils can decrease engine life due to wear.

lubricating oils are not “break-in” Special recommended for a new or rebuilt engine. Use the same type of oil during the “break-in” as specified for normal operation.

Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A. Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines.” The data book may be ordered from the Engine Manufacturers Association, 401 North Michigan Avenue, Chicago, IL U.S.A. 60611. The telephone number is (312) 6446610.

Arctic Operation If an engine is operated in ambient temperatures consistently below -23°C (-lOOF) and there are no provisions to keep the engine warm when it is not in operation, use a synthetic API performance

classification CE or CF-4 engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-30.

The oil supplier must be responsible for meeting the performance service specifications.

IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals can decrease engine life due to factors such as; corrosion, deposits and wear.

3-11

MAINTENANCE 2. ENGINE OIL Use API performance classification

CE engine oil.

equipment hydraulic system in cold areas, return to SAE 1OW when the cold season ends.

When using SAE 5W-20 engine oil in the work

3. AXLE OIL For axle oil, use only the recommended oil as follows: SHELL: CALTEX: CHEVRON: TEXACO: MOBIL:

DONAX TT or TD RPM TRACTOR HYDRAULIC FLUID TRACTOR HYDRAULIC FLUID TDH OIL MOBIL AND SUPER UNIVERSAL

f

It is possible to substitute engine oil SAE 30W API classification CD for axle oil. Although increased brake noise may result, durability should not be affected.

4. GREASE

The recommended lubricating grease is No. 2 multipurpose lithium grease with 3% molybdenum disulfide.

5. DIESEL FUEL

A

WARNING! Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.

At operating temperatures below -12°C (+ lO”F), use ASTM Grade No. 1-D diesel fuel. The use of lighter fuels can reduce fuel economy.

to the precise tolerances of diesel it is extremely important that the and free of dirt or water. Dirt or can cause severe damage to both and nozzles.

Where a winterized blend of Grade No. 2-D and No. 1-D fuels is available, it may be substituted for Grade No. 1-D fuel. However, it is the supplier’s responsibilty to provide the fuel for the anticipated ambient temperature.

For normal service above -12” C (+ 10” F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent misfires and excessive smoke.

Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature. Cloud point is the temperature at which crystals begin to form in the fuel.

IMPORTANT: Due injection systems, fuel be kept clean water in the system the injection pump

The viscosity of the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication.

6. COOLANT General Selection and maintenance of the engine coolant is important to long engine life. The following information provides recommendations for selecting the engine coolant and maintaining the coolant inhibitors.

Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant Supplemental coolant additive additives.

3-12

recommendations are included in the section entitled “Inhibitors/Conditioners”.

The coolant mixture must be drained and replaced at the specified service interval shown in the “SCHEDULED MAINTENANCE GUIDE” or every two years of operation, whichever comes first.

MAINTENANCE Water Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited water must meet the following standards: Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits.

Water containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount will cause scale deposits to develop in the engine.

Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.

Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.

Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale deposits, corrosion or a combination of these.

If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water supplies meet these standards, water samples can be tested by water treatment laboratories.

“Softened” water that is prepared using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used.

NOTE: Never use water alone in the cooling system because corrosion will occur.

Antifreeze In climates where the temperature is above -37°C (-34”F), use a coolant mixture that contains 50 percent antifreeze. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is required. Never use more than 68 percent antifreeze under any condition.

An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze concentrations between 68% and 100% actually have a higher freezing point than a 68% antifreeze concentration and should not be used due to reduced heat transfer rates.

Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel formation can occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive. DO NOT use methanol

or alcohol as an antifreeze because of its low boiling point.

Antifreeze may retain its freeze protection than one season but coolant conditioners added to maintain corrosion protection.

for more must be

Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.

NOTE: Do not mix types of antifreeze solutions.

Mixed solutions make it impossible to determine the protection against freezing.

Antifreeze containing sealer or anti-leak additives should NOT be used in this system.

Sealer or anti-leak additives will cause plugging problems in the cooling system.

Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection against freezing.

The following table shows the approximate percentage of antifreeze solution required for various temperatures.

3-13

MAINTENANCE

Approximate Freezing Point +32"F +2O"F +lO"F

(0°C) (-7y ;;;o;;

-40°F -50"F -60°F -70°F -60” F -90°F -92°F

Specific Gravity at 60°F (16°C)

0 15 25 33 40 45

1.000 1.025 1.040 1.053 1.062 1.070

El::;

46 53

1.074 1.069

[$;I

56

1.083

g::;

59 62

1.066 1.092

65 67 68

1.095 1.097 1.098

0°F -10°F -20°F -30"F

Percentage of Antifreeze Concentration

by Volume

@9q

In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor DCA4, to protect the engine cooling system.

Inhibitors/Conditioners

All cooling system inhibitors, including those in antifreeze solutions, become depleted through normal operation. If the inhibitors in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and attacks and coats the metallic surfaces of the cooling system which Cooling system reduces heat transfer. conditioners which contain these inhibitors must be added to maintain corrosion protection.

SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer.

There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still the best coolant.

3-14

4. DCA4 is recommended to inhibit corrosion in the cooling system for the following reasons: l

Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over concentration occurs.

l

Provides engine protection in the following areas: - Solder corrosion/bloom - Copper corrosion/erosion/stress cracking - Oil fouling - Cylinder liner cavitation corrosion - Aluminum cavitation corrosion - Seal and gasket degradation

MAINTENANCE MAINTENANCE OF COOLING SYSTEM INHIBITORS Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and corrosion.

New machines are delivered with antifreeze protection. Service at regular scheduled interval specified in theSCHEDULED MAINTENANCE GUIDE”

with a “service” DCA4 filter. Each time the coolant is drained and replaced, the coolant must be recharged with DCA4. New coolant can be correctly charged with supplemental coolant additives by using DCA4 filters or DCA4 concentrate listed in the table entitled, “DCA4 Unit Guide”.

If coolant is added between drain intervals, additional DCA4 will be required.

COOLANT TESTING FOR CONDITIONER CONCENTRATION When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The DCA4 concentration must not fall below 1.0 unit per 3.8 r! (1 US gal) or exceed 2 units per 3.8 P (1 US gal) of coolant. The only accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis. For this reason, the coolant inhibitor should

be maintained as shown MAINTENANCE GUIDE”.

in

the

“SCHEDULED

NOTE: Inadequate concentration of the coolant additive can result in major corrosive damage to cooling system components. Over concentration can cause formation of “gel’ that can cause restriction, plugging of passages and overheating.

REPLENISHING COOLANT CONDITIONER Install a “precharge” DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss occurs. Install a “service” DCA4 filter as specified in the “SCHEDULED MAINTENANCE GUIDE”. When antifreeze is added, add coolant conditioner equal to 1.0 unit per 3.8 P (1 US gal) of antifreeze.

NOTE: Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no test kit available to measure concentration levels with mixed chemical solutions.

DCA4 UNIT MAINTENANCE GUIDE Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze alone does not provide enough corrosion protection for a heavy duty diesel engine.

Supplemental corrosion protection must be supplied through periodic additions of supplemental coolant additives to the coolant.

To protect against corrosion, a new coolant charge must be brought up to 0.26 DCA4 unit per liter [one unit per U.S. gallon] of coolant (initial charge).

Maintain the correct DCA4 concentration by changing the service coolant filter at each engine oil and filter change interval.

Each time the coolant is drained and replace, the coolant must be recharged with supplemental coolant

additives. Use the appropriate DCA4 spin-on filter listed in following table. The coolant mixture must be drained and replaced as defined under “General”.

The amount of replacement inhibitor is determined by the length of the service interval and the cooling system capacity. Refer to the DCA4 Unit Guide for the selection of the correct filter to replenish the DCA4.

If coolant is added between drain intervals, additional DCA4 will be required. Check the coolant DCA concentration level anytime make-up coolant is added to the system. The DCA4 concentration must not fall below 0.13 units per liter or exceed 0.5 units per liter [0.5 units per U.S. gallon or exceed 2 units per U.S. gallon].

3-15

MAINTENANCE DCA4 Unit Guide Fleetguard Part No.

DCA4 Units

DCA4 Coolant Filter WF-2070 WF-2071 WF-2072 WF-2073 WF-2074 WF-2075 WF-2076 WF-2077

2 4 6 8 12 15 23 0

DCA4 Liquid DCA6OL DCA80L

4 (1 Pint) 1760 (55 US gal)

DCA4 Powder DCA95

20

DCA4 Precharge System Capacity Liters

Gallons

19-26 30-38 42-57 61-76 80-114 118-190

5-7 8-10 11-15 16-20 21-30 31-50

and Service Filters

Precharge Filter (See NOTE 1)

Service Filter (See NOTE 3)

WF-2072 WF-2073 WF-2074 WF-2075 WF-2076 (See NOTE 2)

WF-2070 WF-2071 WF-2071 WF-2071 WF-2072 WF-2073

NOTE: When performing service which requires draining the cooling system, discard the coolant Reusing coolant can introduce contaminates or over concentrated chemicals, resulting in premature failure of cooling system components

NOTE 1 - After draining and replacing coolant, always precharge the cooling system to maintain the DCA4 concentration between 1.0 and 2.0 units per 3.8 P (1 US gal).

NOTE 2 - To precharge cooling systems larger than 114 Q(30 gal) do the following: l

l

units The answer represents the additional required to precharge the cooling system. Four bottles of powder, part number DCA95, will provide a sufficient amount of DCA4 units (80) to precharge the example cooling system.

l

Install the appropriate service filter at the next and subsequent maintenance intervals.

Install appropriate service filter listed in the above table based on cooling system capacity.

Example:

3-16

95 gal (360 P)cooling system capacity -15 Units (1) WF-2075 Filter 80 Units

MAINTENANCE NOTE 3 - Change the coolant filter at every engine oil and filter change interval to protect the cooling system.

concentrated coolant solution. More than 2.0 units per 3.8 0 (1 US gal) indicates an over-concentrated coolant solution.

Maintain a nominal concentration of 1.O DCA4 unit per 3.8 P (1 US gal) of coolant in the system. Less than 0.5 unit per 3.8 0 (1 US gal) indicates an under-

To check the DCA4 concentration level, use the Fleetguard coolant test kit, CC2626. Instructions are included with the test kit.

DCA4 Unit Concentration

Guide

Coolant Condition

Action Required

0 - 10 Drops

Extremely under-concentrated less than 0.4 DCA4 units per 3.8 P (1 US gal)

Initially charge the system to a minimum of 1.0 DCA4 unit per 3.8 e (1 US gal).

11 - 16 Drops

Marginally under-concentrated 0.45 to 0.8 DCA4 units per 3.8 e (1 US gal)

Add DCA4 liquid units to maintain 1.0 DCA4 unit per 3.8 P (1 US gal) minimum or change the DCA 4 coolant filter.

17 - 25 Drops

Acceptable - 0.85 to 1.3 DCA4 units per 3.8 P (1 US gal)

None.

26 - 35 Drops

Highly acceptable - 1.35 to 2.0 DCA4 units per 3.8 4 (1 US gal)

None.

36 - 55 Drops

Marginally over-concentrated - 2.1 to 3.3 DCA4 units per 3.8 4 (1 US gal)

Review maintenance

Over 55 Drops

Extremely over-concentrated

Drain 50% of the coolant and replace with water antifreeze mixture. Retest the system for correct DCA4 unit concentration.

Number of Solution A Drops to Cause Color Change

practice.

3-17

MAINTENANCE MEMORANDUM

3-18

MAINTENANCE SCHEDULED

MAINTENANCE

Scheduled maintenance is the normal maintenance necessary to provide proper and efficient equipment operation. To protect your investment and prolong the

service life of your equipment, follow the scheduled maintenance listed below.

ITEM

SERVICE

Transmission oil filter Normal 250 hour scheduled

GUIDE

I

- DCA4

Replace elements

3-25

I Refer to “EVERY 500 HOURS SERVICE�

maintenance

Coolant additive concentration

PAGE

WHEN REQUIRED I Check and supply I

I 3-25

Air cleaner element

Check, clean or replace

3-25

Transmission

Check and refill

3-28

Radiator core

Clean

3-28

Windshield washer tanks

Check and refill

3-29

Drive axle oil level

Check and refill

3-29

oil level

Drive axle housing breathers

I Clean

1 3-30

I

I I

Lubrication: Work equipment control valve linkage Accelerator pedal linkage Brake control linkage _ Steering column

Lubricate Lubricate Lubricate Lubricate

Bucket bolt-on cutting edge - if equipped

Reverse or replace

3-33

Bucket teeth - if equipped

Replace

3-33

Parking brake

Check and adjust

3-35

Lever length

Adjust

3-36

Clean

3-36

Check

3-37

Air conditionner Air conditioner

condenser - if equipped refrigerant charge - if equipped

2 1 3 1

points point points points

3-31 3-31 3-32 3-32

3-19

MAINTENANCE ITEM

SERVICE

PAGE

Steering: Steering wheel is heavy Steering wheel is loose

Check oil level Check oil level and/or grease

3-38 3-38

Hydraulic system: Bucket lacks lifting power Bucket lifting speed is slow Many bubbles form in oil Oil pressure is too low Cylinder vibrates when operating

Check oil level Replace hydraulic tank filter Check oil level & bleed air Check oil level & bleed air Check oil level

3-38 3-38 3-38 3-38 3-38

;. ..:,,

.

‘.

,.

.:~~ECK~:BE~~~E,STA~~~N~~ E&I,NE ‘,‘,,

..

.A.. .“.Z.‘.‘,

,,,.,:::.:_j:. ,” ,:’ . . . ..

Walk around check

2-46

Monitor panel

Check

2-46

Coolant level

Check and refill

2-47

Air cleaner service indicator

Check

2-47

Engine oil level

Check and refill

2-48

Fuel level

Check and refill

2-48

Brake oil level

Check and refill

2-49

Fuel-water separator

Drain water

2-49

Parking brake

Check function

2-50

Wheel brakes

Check function

2-50

Horn

Check function

2-50

Lamps

Check function

2-50

Rear view mirror

Check

2-50

Exhaust gas color and sound

Check

2-50

Gauges and instruments

Check function

2-50

Steering

Check function

2-50

Back-up buzzer

Check function

2-50

Air intake piping

Damage, cracked hoses and loose clamps

2-50

Electrical wiring

Check

2-50

3-20

MAINTENANCE ITEM

,. ,.

:‘.

,.

SERVICE

..,

.‘,

‘:‘::.:

,..

‘...

PAGE

,..,

.

“..

,EVER*: 50, HOti% SERVb ;; ,: “’ ‘,

: :

Drain water and sediment

Fuel tank Tires

I

;.’

.

..

Check air pressure and for damage

3-39 I

3-39

.EVEFY 166 ;HiUR$:,SE@CEi ..,. ,/,A .’

Hydraulic tank oil level

Check and refill

3-39

Lubrication: Bucket pins Bucket link pins Rear axle pivot pins

Lubricate 2 points Lubricate 2 points Lubricate 2 points

3-40 3-41 3-41

Clean elements

3-41

Cab air filter - if equipped Air conditioner

I

filter - if equipped

Clean

EVERY 250.140~~s

I

SERVICE

I

I

Lubricating: Tilt lever pin Dump cylinder pin Lii cylinder pin Lift arm pivot pin Steering cylinder pin

Lubricate Lubricate Lubricate Lubricate Lubricate

Wheel hub bolts

Check and re-tighten

1 2 4 2 4

points points points points points

Engine oil pan and filter

I Change oil and replace filter element

Battery electrolyte

I Check fluid level

Air intake system Air conditioner

compressor

belt - if equipped

3-41

3-42 3-43 3-43 3-43 3-43 3-44 3-44 I

3-45

Check

3-46

Check tension and condition

3-46

EVERY 5.90 HOURS.SERVlCE

I

I

Lubrication: Center drive shaft spline Center hinge pin

Lubricate 1 point Lubricate 2 point

Fuel filter

Replace cartridge

3-47 3-47 I

3-46

3-21

MAINTENANCE ITEM Transmission oil filter Antifreeze concentration Air dryer - if equipped

SERVICE I I I

Replace elements Check

3-50

Check

I

3-50

Lubrication: Front drive shaft Drive shaft center support Center driie shaft Rear drive shaft

Lubricate Lubricate Lubricate Lubricate

Transmission

case breather

Clean

3-53

Transmission

oil and strainer

Change oil and clean strainer

3-53

Engine valves

Check and adjust clearance

3-54

Drive belt

Check tension

3-57

Drive belt tensioner bearing and hub bearing

Check

3-57

Change oil

3-58

Replace element

3-60

Drive axles

I

Hydraulic tank breather

I

2 1 2 2

points point points points

Hydraulic tank and filter

Change oil and replace element

Brake disc

Check

Vibration damper Cooling system Air conditioner

3-22

I

I I

Check

I Check coolant and flush the system filter - if equipped

3-51 3-51 3-52 3-52

Replace element

3-61 3-62 362

II 363 I

3-65

MAINTENANCE OIL FILLER AND LEVEL GAUGE POSITIONS

1.

2.

3.

4.

Hydraulic tank oil filler Hydraulic tank level gauge Hydraulic tank drain plug Transmission case level gauge and oil filler

5. Transmission case drain plug 6. Front axle drain plug 7. Front axle level plug and oil filler

3-23

MAINTENANCE

17

16 15

14 13 12 LO2ZZO82

8.

9.

10.

11.

12.

3-24

Cooling water inlet Engine oil pan level gauge Engine oil pan oil filler Brake oil tank oil filler Rear axle level plug and oil filler

13.

14.

15.

16.

17.

Rear axle drain plug Engine oil pan drain plug Fuel tank drain valve Cooling water drain valve Fuel tank oil filler

MAINTENANCE INITIAL 250 HOURS SERVICE ONLY Perform the following

maintenance only after the first

TRANSMISSION For details of the method of replacing or maintaining,

250 hours.

OIL FILTER see the section on “EVERY 500 HOURS SERVICE”.

WHEN REQUIRED COOLANT ADDITIVE CONCENTRATION *

Inadequate concentration of can result in major corrosive system components.

Over cause restriction, plugging overheating.

- DCA4

the coolant additive damage to cooling concentration can of passages, and

The cooling system must contain the proper coolant additive units to provide the best chemical protection.

DCA4 Test Kit: use only DCA4 Coolant Test Kit, Fleetguard Part No. CC-2600 to check the coolant additive concentration in the cooling system. f

Check once every 6 months, regardless of the number of hours operated.

Check and service. For the detailed procedure, refer to the Engine Operation and Maintenance Manual.

AIR CLEANER ELEMENT CHECKING Whenever the red piston in service indicator (1) appears, clean the air cleaner outer element. Stop the engine when cleaning the element.

3-25

MAINTENANCE CLEANING OR REPLACING OUTER ELEMENT

A

WARNING! Do not clean or replace the air cleaner element with the engine running.

1.

Remove cover wing nut (2) and remove cover (3).

2.

Remove wing nut (4) and remove outer element.

3.

Clean the air cleaner removed cover.

4.

Clean and inspect the element. (See the item “Cleaning outer element� for cleaning procedure.)

5.

Install the cleaned element.

6.

Push the service indicator reset button to return the red piston to the original position.

*

Replace the outer element which has been cleaned six times repeatedly or used throughout a year. Replace the inner element at the same time.

*

Replace both inner and outer elements when the service indicator red piston appears soon after installing the cleaned outer element even though it has not been cleaned six times.

*

Remove one seal from the outer element. The number of times the outer element has been cleaned can be seen by the number of removed seals.

*

Check inner element mounting nuts for looseness and, if necessary, re-tighten.

*

Replace seal washer (5) or wing nut (4) if they are damaged.

body

interior

and the

REPLACING INNER ELEMENT

A

WARNING! Do not clean or replace the air cleaner element with the engine running.

1.

First remove the end cover and the outer element, and then remove the inner element.

2.

Place a protective cover over the air intake part to prevent dust from entering.

3.

Clean the air cleaner body interior, then remove the cover from the air intake port.

A 3-26

WARNING! Do not attempt to reinstall a cleaned inner element.

4.

Install a new inner element and tighten nuts.

it with

5.

Install the outer element and the end cover. Push the service indicator reset button.

MAINTENANCE CLEANING OUTER ELEMENT

Using compressed air

A

A

WARNING! Do not clean or replace the air cleaner element with the engine running.

WARNING! When using compressed air, wear safety glasses and other things required to maintain safety.

Direct dry compressed air, less than 7 kg/cm* (100 PSI / 689 KpA), to element from inside along its folds, then direct it from outside along its folds and again from inside. Check element as follows.

Using water NOTICE:

The following method requires a spare element.

Wash the element with city kg/cm* (43 psi / 296 kPa) inside along the folds, then again from the inside. Dry the follows.

water at less then 3 of pressure, from the from the outside and element and check it as

Using water with cleaning agent NOTICE:

The following method requires a spare element.

For removing oil and grease as carbon etc. on the element, the element may be cleaned in a lukewarm solution of mild detergent, then rinsed in clean water and left to air dry. f-

Using warm water at about 40°C (104’F) instead of soapy water may also be effective.

*

The drying process can be speeded up by applyin? dry compressed air, at less than 7 kg/cm (100 PSI / 669 KpA), to the element from the inside to the outside of the element.

LlZAVO15

NOTICE:

Never attempt to heat the element.

*

If small holes or thinner parts are found on element when it is checked with an electric bulb after cleaning and drying, replace the element.

*

If element is usable, wrap it and store it in dry place.

*

Do not use element whose folds or gasket or seal are damaged.

A

When cleaning element, do not hit it or beat it against something.

3-27

MAINTENANCE TRANSMISSION

OIL

Carry out this procedure if there is any sign of oil on the transmission case, or if there is oil mixed with the cooling water.

A

WARNING! When checking the oil level, apply the parking brake, and lock the front and rear frames with the safety bar and pin.

*

After the engine is operated for 5 minutes, check the oil level of the transmission in neutral position at the engine low idling.

1.

Start the engine and remove the cap of oil filler (F).

2.

Use the oil level gauge marked on dipstick (G) to check the oil level.

3.

The oil level should be between mark L and H, if necessary, add oil at the oil filler tube (F).

*

The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS.�

RADIATOR CORE Carry out this procedure if there is any mud or dirt stuck to the radiator and/or oil cooler.

1.

Loosen the four mounting radiator grille (2).

2.

Clean the radiator core and oil cooler that are clogged with mud, dirt, etc., with compressed air.

Steam or water may be used instead of compressed air.

*

When cleaning the radiator core and oil cooler, choose a 2 mm (0.07 in) diameter nozzle (3) and use high pressure water at a pressure less than 40 kg/cm (569 psi / 3923 kPa).

*

If it is impossible to remove all mud and dirt when cleaning from the radiator grille side of oil cooler (4), remove engine fan guard (6) and clean from the front side of radiator (5).

*

Hydraulic oil hoses should be checked at the same time. If a hose is found to have cracks or to be hardened by aging, such a hose should be replaced by new one. Furthermore, check for loosened hose clamps.

3-28

bolts (1) and remove

MAINTENANCE WINDSHIELD WASHER TANKS Check the liquid level in washer tank (1) and (2)..

Add automobile window washer liquid if necessary. f

Be careful not to let dirt get in the tank when adding the liquid.

Front window wahing fluid tank Rear window wahing fluid tank t

,

f

>

5 >

i i

U3DVOli

DRIVE AXLE OIL Carry out this procedure if there is any sign of oil on the axle housing.

Front

Remove oil level plug (1) and (2) and check that the oil level reaches the bottom of the plug hole. If necessary, add oil through the hole of plug (3) and (4). *

The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS”.

Rear

h

I

I L07FR04:

3-29

MAINTENANCE Some machines have a plug with a dip stick (1).

To check the oil level; 1.

Remove plug (with dip stick).

2.

Wipe off the dip stick portion with a service rag.

3.

Insert the dip stick so that the bottom of the plug is off set and level with top of plug hole (1).

4.

Remove the dip stick and read the oil level.

5.

After checking Plug-

and servicing,

reinstall

the

I-

DRIVE AXLE HOUSING BREATHERS Carry out this procedure if there is any mud or dirt stuck around the breather.

Remove all mud and dirt from around the breather with brush. *

Clean the breathers of the front and rear drive axles in the same way.

3-30

L07FR04

MAINTENANCE

LUBRICATING Apply grease to the grease fittings shown by arrows.

1.

Work equipment control valve linkage (2 points) If the work equipment control lever is heavy or does not move smoothly, apply grease.

2.

Accelerator

pedal linkage (1 point)

If the accelerator pedal is heavy or does not return properly, apply grease.

3-31

MAINTENANCE 3.

Brake control linkage (3 points) If the brake pedal is heavy or does not return properly, apply grease.

4.

Steering column (1 point) If the play of the steering column is heavy or does not return properly, apply grease.

L07CH037

3-32

MAINTENANCE BUCKET

BOLT-ON

CUlTING

If the bolt-on cutting edge is worn, turn the edge.

I

1.

Raise the bucket to a convenient height, and put blocks under the bucket to prevent it from coming down.

*

Raise the bucket so that the bottom is horizontal.

2.

Loosen nut (1) and remove bolt (2). Then, turn the cutting edge.

3.

Exchange cutting edges (3) and (4) and install edge (5) in the opposite direction.

4.

After exchanging, tighten with bolts (2) and nuts (1).

Tightening torque: 40 - 54 kgm When installing the edge to the bucket, clean the mounting surface.

After the edge has been turned once, replace it with a new part.

* * *

BUCKET

EDGE - IF EQUIPPED

TEETH

- IF EQUIPPED

BUCKET IS EQUIPPED WITH BOLT-ON TEETH When the bucket teeth are worn, replace them as follows.

*

1.

Raise the bucket to a convenient height, and put blocks (A) under the bucket to prevent it from coming down.

*

*

Position the horizontal.

2.

Remove the mount bolts and nuts (1) and bucket teeth (2).

3.

Install the new teeth on the bucket. When installing each tooth, insert a shim(s) so that there is no clearance between the tooth and the top surface of the bucket.

*

Continue to adjust with shims until it becomes impossible to insert a shim of thickness 0.5 mm.

4.

To prevent any clearance between the tooth and the edge of the bucket, tighten the mount nut partially, then hit the tip of the tooth with a hammer.

Tightening torque of mounting bolts:

64 t

3

kgm After operating the machine for a few hours, tighten the mounting bolts again.

I bucket

so that

the

bottom

is

I

Ll7DHOlO

3-33

MAINTENANCE BUCKET IS EQUIPPED WITH WELDED REPLACEABLE TIP TEETH

ON OR

Replace the teeth before they wear down as far as the adaptor.

1.

Extract pin (2) fitted to the bucket and then remove tooth (1).

*

When extracting pin (2), strike the part (either the left or right part) with a sharp object. This will enable the pin td be extractedfrom the opposite side.

2.

Insert the new tooth (1) onto the adaptor (3), and insert pin (2) partway as shown in the diagram.

Then drive it home by means of a hammer.

3-34

LVDHOll

MAINTENANCE

PARKING B AKE INSPECTION If 12 or more ratchets are counted before the parking brake comes into effect, perform the following adjustment.

ADJUSTMENT

A

WARNING! Install blocking in front of and behind the wheels before adjusting the parking brake.

1.

Move lever (1) back fully to release caliper (5).

2.

Loosen lock nut (2) and remove clevis pin (4).

3.

Adjust with adjustment bolt (7) so that clearances (A) and (B) between the disc and pad are 0.05 0.2 mm.

4.

Push up by an amount equal to clearance of the caliper lever, and screw in clevis (3). Align the pin hole of caliper lever (S), then assemble clevis pin (4) and tighten locknut (2).

*

Don’t tighten adjusting bolt (7) too much.

*

After adjusting, make sure that there is no play of adjustment bolt (7) in the axial direction.

*

After adjustment, check the stroke when the lever is pulled (approx. 5 kg) three or four clicks from released position.

NOTICE:

When the thickness (including lining) of a pad wears out to 7 mm or less, replace the pad.

*

Replace two pads as one set, and replace the retraction plate (8) at the same time.

*

Have the pads replaced by your distributor.

A

LCI4AZOlS

7mm .:: :2 :: ,_: IF

WARNING! Do not get any oil or grease on the surface of the brake pad or disc.

3-35

MAINTENANCE LENGTH

OF LEVER

ADJUSTING It is possible to adjust the length of the directional lever and speed control lever.

1.

Pull out knob (1).

2.

Loosen locknut (2) and turn bolt (3) to adjust.

3.

After adjusting, tighten locknut (2) and push in knob (1) fully.

-k

Keep distance (L) under 43 mm. If it is not screwed in far enough it is dangerous.

LO8BZOO2

LOSBZOO~

AIR CONDITIONER

CONDE

If there is mud or dust on the air conditioner condenser, clean it with water. *

If the water pressure is too high, the fins may get deformed. When washing with a high pressure washing machine, apply the water from a reasonable distance.

A

3-36

WARNING! Do not clean the condenser with a stream cleaner. The condenser will become hot and may be damaged.

rlSER - IF EQUIPPED

MAINTENANCE

AIR CONDITIONER

REFRIGERANT CHARGE - IF EQUIPPED

Check the air conditioner refrigerant charge twice a year, in spring and autumn.

The sight glass is located on the air conditioner dryer receiver, which is located on the right side of the machine next to the condenser.

Operate the air conditioner for 5 - 10 minutes at the coolest setting, then touch the high pressure hose and low pressure hoses at the refrigerant compressor by hand. Next, check the flow of refrigerant gas (freon 12) through the sight glass to check the gas level.

A

Contact your distributor

for this inspection.

NORMAL

CONDITION

WARNING! Air conditioner refrigerant is colorless and odorless and does not cause pollution of the atmosphere, if handled properly. However, it may cause injury if it gets in the eyes or on the hands, so never loosen any parts of the refrigerant system.

ABNORMAL

Temperature of high & low pressure lines

High pressure line is hot Low pressure line is cold Clear difference in temperature

High pressure line is warm Low pressure line is cold Little difference in temperature

Almost no difference in temperature between high & low pressure lines

Sight glass

Almost transparent. Any bubbles disappear if engine speed is raised or lowered.

Bubbles are always flowing. Sometimes becomes transparent or white bubbles appear.

Misty substance is flowing.

Q

@

@

System line connections

Properly connected

Some parts dirty with oil

Some parts very dirty with oil

General condition conditioner

Refrigerant level correct, no abnomalities. Ready for use.

May have refrigerant leak. Contact your distributor for inspection and repair.

Almost all refrigerant has leaked out. Contact your distributor for immediate repair.

of air

3-37

MAINTENANCE STEERING Steering wheel is loose

Steering wheel is heavy l

Add oil to the specified level.

HYDRAULIC

l

Apply grease to steering cylinder pin.

0

Add oil.

SYSTEM Oil pressure is too low

Bucket lacks lifting power Bucket lifting speed is slow.

l l

Add oil.

l

Replace filter in hydraulic tank.

Add oil and bleed air.

Cylinder vibrates when operating l

Add oil.

Many bubbles form in oil l

Replace with specified oil.

l

Add oil.

l

Bleed air from oil line.

SERVICE

METER

This meter indicates the integrated work hours. So, use it according to the following instructions.

0

Record the readings at the start and end of work, this is the work record of the machine.

0

This record will indicate, maintenance is due.

0

It also indicates the integrated working when machine problems are encountered.

*

How the meter progresses

when

periodical

hours

J

The service meter progresses by 1 when the engine is operated for one hour, regardless of the engine speed.

Consequently, if the machine is running, the service meter will advance even if the machine does not move.

3-38

LllAZ005

MAINTENANCE CHECK BEFORE STARTING See the section on CHECK BEFORE STARTING aforementioned

in SECTION 2.

EVERY 50 HOURS SERVICE FUEL TANK Loosen valve (1) on the bottom of the tank so that the precipitation and mixed water will be drained in accompaniment with fuel.

I

U2BD037

TIRES Measure the inflation pressure before operations when the tires are cool. Refer to HANDLING TIRES.

Also, at this time, check for tire damage.

EVERY 100 HOURS SERVICE *

Maintenance for every 50 hours should carried out at the same time.

be

HYDRAULIC TANK 1.

Lower the bucket horizontally to the ground and stop the engine. Wait for 5 minutes, then check sight gauge (G). The oil should be visible in sight gauge (G).

2.

Add engine oil at the oil filler (F), if necessary.

A *

WARNING! When removing the cap, turn it slowly to relieve inner pressure.

The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS.”

3-39

MAINTENANCE LUBRICATING Apply grease fiiings

A

1.

shown by arrows.

WARNING! Before starting the greasing service, fully dump the bucket, lower it to the ground, lock the work equipment control lever, apply the parking brake, and stop the engine.

Bucket pin (2 points)

3-40

MAINTENANCE 2.

Bucket link pin (2 points)

3.

Rear axle pivot pin (2 points)

CAB AIR FILTER AIR CONDITIONER Clean the cab air filter as follows: Clean the air conditioner filter as follows: *

Be sure the cab blower fan is stoooed *. cleaning the filter elements.

*

Direct dry compressed air (less than 7 kg/cm* [lo0 psi / 689 kPa]) to the element from the inside along its folds, then direct it from the outside along its folds and again from the inside.

Check the element for damage and/or deterioration.

A 1.

2.

- IF EQUIPPED

FILTER

- IF EQUIPPED

3.

Remove filter mounting screws, flat washers and nuts securing filter. Remove filter mounting bolts securing filter. Pull out the two filters and clean them.

4.

Reinstall filters (3) and access oanel (1). Move seat back to its original position.’ ’ ’

before

When using compressed air, wear safety glasses and other things required to maintain safety.

WARNING!

Move the operator’s seat forward, seat backrest forward and down.

then tilt the

Loosen access panel thumb screws (2) and move access panel (1) to gain access to filters (3).

I

v Ll3FD037

3-41

MAINTENANCE EVERY 250 HOURS SERVICE f

Maintenance for every 50 hours and 100 hours should be carried out at the same time.

LUBRICATING Apply grease to the grease fittings shown by arrows.

A

1.

WARNING! Before starting the greasing service, fully dump the bucket, lower it to the ground, lock the work equipment control lever, apply the parking brake, and stop the engine.

Tilt lever pin (1 point)

3-42

MAINTENANCE 2.

Dump cylinder pin (2 points)

I

3.

Lii cylinder pin (4 points)

4.

Lii arm pivot pin (2 points)

LO2AVO681

r._.

5.

.?

LO2AVO69

Steering cylinder pin (4 points)

3-43

MAINTENANCE WHEEL

HUB BOLTS

If wheel hub bolts (1) are loose, tire wear will be increased and accidents may be caused. If any hub nuts are loose, tighten them to the specified tightening torque. *

Tightening

torque:

94.5 + 10.5 kgm

*

If any wheel bolt is broken, replace all bolts for that wheel.

*

Always rotate in the direction of tightening checking for loose bolts.

ENGINE 1.

when

OIL PAN AND FILTER

Warm up the engine to operating temperature and the trun the engine off.

A

WARNING! If oil filter (2) is removed immediately after stopping the engine, oil will soill. Wait at least 10 minutes after stopping the engine before replacing the filter.

2.

Open the engine side covers located on the left and right of the engine hood and lock in position.

3.

Open oil filler (F) and remove drain plug (1) to drain oil. After draining, tighten the drain plug.

4.

Clean the area around the oil filter.

5.

Using a filter wrench, remove oil filter (2) by turning it counterclockwise.

6.

Clean the filter gasket surface of the filter header.

7.

Fill a new oil filter with engine oil. Then, apply engine oil or a thin coat of grease to the seal.

To install filter, bring its seal surface into contact with sealing surface of filter base and then tighten the filter l/2 to 3/4 turn by hand. *

Be careful not to tighten it up excessively.

*

Be sure to use a genuine filter.

After replacing the filter, pour in the specified quantity of engine oil at oil filler (F). *

3-44

Refill capacity is 14.3 P (3.8 US gal).

Ll2ZZ17i

MAINTENANCE *

The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS.”

*

Replace once every 3 months, regardless of the number of hours operated.

10. After refilling with oil, start the engine and idle it for a while. Inspect for oil leaks at the filter and drain plug. Then stop the engine and check the oil level. Wait for 5 minutes before checking.

I

11. Close the engine side covers.

*

Diluted oil can cause severe damage to the engine. Check the condition of the used oil.

0 0

Thin, black oil indicates fuel dilution.

Milky discoloration indicates coolant dilution.

BATTERY

A

ELECTROLYTE

WARNING! If the electrolyte gets on your skin or clothes, immediately wash with plenty of clean water.

WARNING! To avoid gas explosions, do not bring fire or sparks near the battery.

A 1.

Open the battery battery caps.

2.

If the electrolyte level is lower than the prescribed level (10 to 12 mm above the plate), add distilled water.

3.

U2AM0011

box covers and remove the

*

Should any of the acid be split, have it replenished by the nearest battery shop with acid of the correct specific gravity.

*

When checking electrolyte level, clean the vent hole of the battery caps.

/

‘%!

’

L08AH029

Reinstall the battery caps and close the battery box covers.

3-45

MAINTENANCE

AIR INTAKE

SYSTEM

Inspect the intake piping for damage, cracked hoses, loose clamps, etc. *

Never operate the engine without an air cleaner.

LlZAROB:

AIR CONDITIONER

COMPRESSOR

DRIVE

BELT - IF EQUIPPED

1.

Open the engine side access door on the right side of the machine.

4

Move the tension.

2.

Visually inspect the drive belt. Replace belts that are cracked or frayed. Adjust belts that have a glazed or shiny surface, indicating belt slippage.

Correctly installed and tensioned belts show even pulley and belt wear.

3)

When proper belt tension is obtained, tighten the arm adjusting bolts (3) and the mounting bracket pivot bolt (2) securely to hold the compressor in place.

3.

Check each belt pulley for damage and pulley groove wear. Particularly, check whether the drive belt is contacting the bottom of the pulley groove through wear. Also, check for pulley alignment.

4.

Check belt tension (1) at the midway point of the longest pulley span using the deflection method.

*

Proper belt deflection is 10 mm (25/64 in) when applying approximately 6 kg (13 Ibf / 58 N) of force on the belt between the compressor drive pulley and the magnetic clutch. If the deflection is more than the specified range, the belt tension must be adjusted.

5.

If necessary, adjust drive belt tension as follows:

1)

Loosen the arm adjusting bolts (3) and the mounting bracket pivot bolt (2).

*

When adjusting drive belt tension, do not attempt to move the compressor directly with a bar or similar tool, but use a wood block to prevent damage.

3-46

compressor

(4) to adjust

belt

6.

Close the engine side access door on the right side of the machine.

*

If proper belt tension can not be obtained, the drive belt may be stretched, leaving no allowance for adjustment, and should be replaced.

*

When the belt is replaced, readjust its tension after running for one (1) hour.

MAINTENANCE

EVERY 500 HOURS SERVICE Maintenance for every 50, 100 and 250 hours should be carried out at the same time.

LUBRICATING Apply grease to the grease fiiing

shown by an arrow.

1.

Center drive shaft spline (1 point)

2.

Center hinge pin (2 points)

3-47

MAINTENANCE FUEL FILTERS GENERAL The fuel filters are spin-on type filters. These filters cannot be cleaned and should not be disturbed except when it becomes necessary to replace them.

Change the fuel filters as listed on the SCHEDULED MAINTENANCE GUIDE or sooner if a power loss is evident. If a power loss persists, consult your distributor.

REPLACEMENT 1.

Open the engine side access cover on the right side of the machine and lock into position.

2.

Clean the area around the fuel filters (1).

3.

Using a filter wrench, remove the fuel filters by turning them counterclockwise. Discard the filters in a suitable manner if they are not needed for any reason.

4.

Clean the filter gasket surfaces of the filter header for each filter. Replace the filter O-rings.

3-48

NOTE: Fuel with more than the average impurities may require changing filters at shorter intervals.

The fuel filters are located on the right side of the engine.

Be careful not to allow dirt, water or other foreign material to get in the new filter. Keep new filters in the original package until ready for installation.

MAINTENANCE 5.

Fill the new filters with clean diesel fuel. Then, apply a thin coat of clean engine oil to the seal of the filter.

6.

Install the filters on the filter header until the filter seal contacts the seal surface of the filter header and then, turn the filter an additional l/2 to 3/4 turn by hand. f

Do not over tighten the filter or damage may result to the filter seal or threads.

*

Use a genuine filter.

I

7.

After replacing the filters, start the engine and idle it for a few minutes. Check the filters for possible fuel leakage.

8.

Close the engine side access cover.

I

LlZBMOOC

LlZAMOZ(

*

Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing the filters or injection pump supply line will be vented automatically, if the fuel filter is changed in accordance with the instructions.

However,

manual

bleeding

will be required

if:

l

The fuel filter is not filled prior to installation.

l

The injection pump is replaced.

l

High pressure fuel lines are replaced.

3-49

MAINTENANCE TRANSMISSION 1.

Remove drain plug (1) at the bottom of the filter case, and drain the oil. After draining the oil, tighten the plug.

2.

Hold case (2) and loosen center bolt (3) then remove case (2).

*

Be sure to use a genuine filter element..

*

Replace the filter gasket and O-rings with new parts. Coat the gasket and O-rings with clean engine oil before installing.

3.

Remove the element, and clean the inside of the case. Assemble a new element, then install the case.

*

Before tightening center bolt (3) install bolt washer (4) so that its chamfered surfaces faces the hexagonal head of the center bolt.

*

Be careful not to apply excessive torque to center bolt (3). *

4.

OIL FILTER

Torque center bolt (3).

Tightening torque: 7.8 ? 1.2 kgm.

Run the engine for a short time at idling speed, then stop the engine. Check that the oil is at the specified level (for details, see WHEN REQUIRED).

ANTIFREEZE CONCENTRATION Use ethyleneCheck the antifreeze concentration. glycol base antifreeze to protect the engine to -37°C year round. See SECTION 2.

AIR DRYER - IF EQUIPPED Replace the following

internal parts of the air dryer:

Desiccant, oil filter, filter, and all rubber parts.

Contact your distributor

3-50

to have these items replaced.

L07BVOOE

MAINTENANCE

EVERY 1000 HOURS SERVICE Maintenance 500 hours

done

every

250 and

be

LUBRICATING Apply grease to the grease fittings shown by arrows.

1.

Front drive shaft (2 points)

LOZAVO7

2.

Drive shaft center support (1 point)

3-51

MAINTENANCE 3.

Center drive shaft (2 points)

I

I

4.

3-52

Rear drive shaft (2 points)

IOZAVO74

/

/

Lb2iN07f

MAINTENANCE TRANSMISSION

CASE BREATHER

Remove all mud and dirt from around the breather, then remove the breather. Put in cleaning fluid and clean the breather.

TRANSMISSION 1.

OIL AND STRAINER

Loosen drain plug (P) to drain oil. After draining off the oil, tighten up drain plug (P). *

After loosening drain plug (P), pull out the plug slowly to prevent the oil spouting out.

2.

Loosen drain plug (1) of transmission oil filter to drain oil. After draining off the oil, tighten up drain plug (1).

3.

Remove bolts (2) and cover (3) then remove strainer (4).

4.

Remove all dirt from the surface of strainer (4) then wash in clean light oil. If strainer (4) is damaged, replace with a new part.

5.

Install strainer (4) in cover (3). Replace the O-ring of the cover with a new part, then install the cover.

3-53

MAINTENANCE 6.

Pour in the specified amount of engine oil from oil filter (F).

7.

After refilling, check the oil level and ensure that it is correct. (Refer to WHEN REQUIRED.) *

Refill capacity: 25 4

*

The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL-COOLANT AND LUBRICANTS�.

*

Check for oil leak at transmission filter.

case and

ENGINE 1.

Remove valve covers (1).

2.

Locate Top Dead Center (TDC) for cylinder number 1 by barring engine slowly while pressing on engine timing pin (2).

Ll222162

3-54

MAINTENANCE 3.

When pin (2) engages the hole in camshaft gear (3) cylinder number 1 is at TDC on the compression stroke.

A

4.

WARNING! Be sure to disengage after locating TDC.

pin (2) : :

Check and adjust the valves indicated by “I” and “E” (I - Intake; E - Exhaust).

0.254 mm Intake clearance: Exhaust clearance: 0.508 mm Check and set valves with engine cold - below 60” C. Ir

5.

The clearance is correct when some resistance is “FELT” when feeler gauge (4) is slipped between the valve stem and the rocker lever.

Tighten the lock nut to 2.48 kgm and re-check the valve lash.

E

6

I

5

4

I

E

3

2

E

I

1

MAINTENANCE 6.

Mark the pulley and rotate the crankshaft degrees. *

380

Be sure timing pin is disengaged.

7.

Set the valves indicated by “I” and “E”.

8.

Tighten the lock nut to 2.48 kgm and recheck the valve lash.

9.

Install valve covers (1)and tighten cap screws to 2.48 kgm.

I

I

3-56

6

Ll222162 1

MAINTENANCE DRIVE BELT 1. Measure the belt deflection at the longest span of

the belt when pressed with the finger.

Maximum deflection:

f

9.5 - 12.7 mm

Cummins belt tension gauge ST-l 293 may be used. The required gauge value is 37 to 49 kg.

DRIVE

BELT, TENSIONER

BEARING

AND FAN HUB

1. Remove drive belt (1) and complete the following

steps: 2.

Inspect the belt for damage.

L02AA020 3.

Check the tensioner bearing. *

The tensioner pulley should spin freely with no rough spots detected under hand pressure.

3-57

MAINTENANCE

4.

Check the fan hub bearing. f

5.

The fan hub should excessive end play.

spin

freely without

Install the drive belt (1).

I n7A

An7fl

EVERY 2000 HOURS SERVICE *

Maintenance for every 50, 100, 250, 500 and 1000 hours should be carried out at the same time.

DRIVE AXLES *

Use the same procedure to change the oil for the front and rear axles.

1.

Remove front and rear oil filler plugs (1 and 2), then remove drain plugs (3 and 4) to drain the oil.

2.

After draining the oil, clean drain plugs (3 and 4) then install them.

3.

Add oil to the specified level through the oil filler ports of the axle housing.

4.

Check the oil level and ensure that is correct.

(Refer to WHEN REQUIRED.)

3-58

Front

1

\

/

L07FM0391

MAINTENANCE ear

*

Refill capacity:

16 P (each axle)

*

The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL. COOLANT AND LUBRICANTS�.

II

I

LO7FR0451

ear

Some machines have a plug with a dip stick (1).

To check the oil level; 1.

Remove plug (with dip stick).

2.

Wipe off the dip stick portion with a service rag.

3.

Insert the dip stick so that the bottom of the plug is off set and level with top of plug hole (1).

4.

Remove the dip stick and read the oil level.

6.

After checking plug.

and servicing,

reinstall

the

1 L

L07FR041

3-59

MAINTENANCE

HYDRAULIC

A

WARNING! When removing the hydraulic tank cap, turn it slowly to relieve inner pressure.

1.

Remove hydraulic tank filler cap (F).

2.

Remove the snap ring on the breather (l), then . . . remove the breather cap.

3.

Replace the filter element with a new part, then install the cap and snap ring.

*

It is possible to replace the element with the breather installed in the tank. However, if the breather is removed, do not wrap the taper thread of the breather with seal tape when assembling again, and be careful not to tighten too much.

3-60

TANK

BREATHER

F

MAINTENANCE HYDRAULIC TANK AND FILTER 1.

Lower the bucket horizontally to the ground and apply the parking brake, then stop the engine.

2.

Remove the cap of oil filler (F) and air vent plug (1)on filter case.

*

WARNING! When removing the cap, turn it slowly to relieve inner pressure.

A 3.

Turn wrench clockwise and hold it, then remove the filler cap by turning it counterclockwise.

Loosen drain plug (2) to drain oil. After draining, tighten the drain plug.

A

WARNING! The filter cover is pushed up by spring tension, so hold the cover down when removing the bolts.

4.

Remove the mounting bolt of filter cover (3) then remove the cover.

5.

Remove spring (4) and bypass valve (5) then remove element (6). *

6.

7.

Check that there is no foreign matter inside the tank before cleaning it.

Install a new element, then install bypass valve (5) spring (4) and cover (3). *

If the O-ring of the cover is damaged deteriorated, replace it with a new part.

or

*

When installing the cover bolts, push down the cover and tighten the bolts evenly.

Pour the specified quantity of engine oil from filler (F).

a. Bleed the air from the hydraulic circuit, lower the bucket horizontally to the ground, and stop the engine. See “BLEEDING AIR FROM CIRCUIT” for the air bleeding procedure.

9.

Check the oil level and ensure that is correct.

(Refer to EVERY 100 HOURS SERVICE.) *

Refill capacity: 63 4

*

The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS”.

*

Check that there is no oil leaking from the filter cover mount.

3-61

MAINTENANCE

BRAKE

DISC

Ask your distributor to check and repair brake disc.

VIBRATION

1.

Check the index lines (A) on the damper hub and the inertia member (B). If the lines are more than 1.59 mm out of alignment, replace the damper.

2.

Inspect the rubber member for deterioration. If pieces of rubber are missing or if the elastic member is more than 3.18 mm below the metal surface, replace the damper.

3-62

DAMPER

MAINTENANCE COOLING SYSTEM

COOLANT

RECOMMENDATIONS

/ SPECIFICATIONS

For coolant recommendations / specifications, refer to “COOlANT” under “LUBRICANTS, FUEL AND COOLANT”.

CHANGING

COOLANT AND FLUSHING SYSTEM

*

Stop the machine on level ground when cleaning or changing the coolant.

*

The antifreeze/DCA4 every two years.

*

Use antifreeze during all seasons to protect the cooling system from corrosion as well as freezing damage.

*

In tropical may be (Cummins the engine

*

A mixture of 50% water and 50% ethylene-glycol base antifreeze is required for operation of the engine in temperature environments above -37” C.

*

Do not operate the engine without a thermostat.

1.

Stop the engine.

*

Check for damaged hoses and loose or damaged hose clamps. Replace as required. Check the radiator for leaks, damage and build up of dirt.

Clean and repair as required.

2.

Turn cap (1) slowly until it comes off.

A

mixture must be changed

climates where antifreeze availability limited, use a corrosion inhibitor liquid DCA), or an equivalent to protect cooling system.

WARNING! Do not remove cap (1) while coolant is hot. Hot coolant may spout out.

When removing radiator cap, lift the lever to relieve inner pressure.

Open drain valve (2) at the right side of the fuel tank and plug (3) in the bottom of the water inlet on the engine side to drain off the coolant.

Drain off all the water, then close up drain valve (2), plug (3), and pour in soft water (ex: city water) up to the vicinity of the water filler.

When the water reaches the vicinity of the water filler, put the engine at low idling, open drain valve (2), plug (3), then pass water through the cooling system for 10 minutes. *

When doing this, adjust the inflow and outflow of water so that the radiator is always full.

3-63

MAINTENANCE 6.

After flushing with water, stop the engine. Close drain valve (2) and drain plug (3) after draining water.

7.

After draining water, clean with a flushing agent. *

If the system shows mineral build-up, scale, rust or oil, use a heavy duty radiator cleaner and follow the manufacturer’s direction.

*

Do NOT use caustic cleaners in the cooling system. Aluminum components will be damaged.

*

Follow the instructions on the label of the flushing agent used to clean the system.

After cleaning the cooling system, again flush system with soft water until clean water flows of the drain openings. Then close drain valve and plug (3) and pour in soft water (ex: water) up to the vicinity of the water filler.

the out (2) city

When the water reaches the vicinity of the water filler, put the engine at low idling, open drain valve (2) and plug (3) then pass water through the cooling system until clean water comes out from drain valve (2) and plug (3). *

When doing this, adjust the inflow and oufflow of water so that the radiator is always full.

10. When the water becomes completely clean, stop the engine, drain water and close drain valve (2) and plug (3). *

During filling, air must be vented from the engine coolant passage. Adequate venting is provided for a fill rate of 30 liters/minute.

11. Fill the cooling system with the correct mixture of water, antifreeze and the correct amount of DCA4.

12. Run the engine for 5 minutes at low idling to eliminate air trapped in the cooling system, and run the engine for 5 minutes at high idling. ((leave water filler cap (1) off during this operation.))

13. Stop the engine and 3 minutes later supply the system with the correct mixture of water, antifreeze and the correct amount of DCA4 up to the bottom of the radiator filler opening.

14. Repeat Steps 12 and 13 to ensure that the coolant mixture is up to the bottom of the radiator filler opening. Install and tighten the radiator cap (1).

3-64

MAINTENANCE AIR CONDITIONER 1. Move the operator’s

FILTER

seat forward, then tilt the

backrest forward.

2.

Open the panel and loosen screw (1) holding filter element (2), pull out element.

3.

Install a new element and close the panel.

4.

Return the operator’s seat to its original position.

FD03q

3-65

MAINTENANCE

MEMORANDUM

3-66

SECTION

4

SPECIFICATIONS

A

WARNING ! REFER TO AND READ ALL SAFETY PRECAUTIONS

IN SECTION

1.

4-1

SPECIFICATIONS GENERAL SPECIFICATIONS ENGINE

Make and Model

KDC 610T diesel engine

Type

4-stroke, water cooled, overhead valve, direct injection, turbocharger

Displacement

5.9 liter (369 ins)

Number of cylinders

Six (6)

Bore and stroke

102 mm x 120 mm (4.02 in x 4.72 in)

Flywheel horsepower @ 2600 rpm

107 kW (144 HP)

Dry, cyclopack air cleaner with dust evacuation valve for longer element service.

All-speed mechanical governor.

Gear-pumpdrivenforce-lubricationwithfull-flowfilters.

All filters are spin-on type for easy maintenance.

24 V/7.9 Kw electric starting motor. alternator. 2 x 12 V/150 Ah batteries.

24 V/45A

TRANSMISSION 3-element, single-stage, single-phasetorqueconverter.

Travel

Forward

Reverse

Full power-shift, counter-shaft type transmission.

A neutral safety circuit allows starting only when directional control lever is in neutral.

AXLES & FINAL DRIVES A spiral bevel gear for reduction and planetary gear, single reduction final drive.

Four-wheel drive system.

A semi-floating front axle is fixed to the front frame.

Center-pin-supported, semi-floating rear axle with a oscillation of * 12.5�.

Front and rear torque proportioning differentials minimize tire slippage on soft or wet terrain.

BRAKES Service brakes: Hydraulically actuated, inboardmounted, wet, disc brakes actuate all four wheels.

Two pedals are provided. Both can be used for normal braking; however, the left pedal can be used for braking and transmission neutralizing simply by actuating a switch.

4-2

Parking brake: Dry disc type applied on front output coupling of the transmission.

SPECIFICATIONS

STEERING SYSTEM Center-pivot frame articulation.

Orbital type, fullhydraulic steering independent of the engine RPM’s.

HYDRAULIC A gear pump for steering and loader control.

Capacity Loader

A wide articulation angle of 40” on each side for a minimum turning radius of 18’9” or 5730 mm at the outside corner of the bucket.

SYSTEM Hydraulic Hydraulic cylinders

(discharge flow) at engine 2400 RPM 51.3 U.S. gal/min 205 Itr.

Relief valve setting Loader 2990 psi Steering 2700 psi

210 kg/cm’ 190 kg/cm’

cylinders Number

Bore

Stroke

cylinders

5

Control valves A 2-spool type control valve.

Hydraulic cycle time (rated load in bucket) Raise 5.8 sec.

Dump 1.5 sec.

Lower (empty) 3.2 sec.

SERVICE REFILL CAPACITIES Cooling system Fuel tank Engine Brake oil tank

10.0 U.S. gal.

44.9 U.S. gal.

5.0 U.S. gal.

0.3 U.S. gal.

38 Itr. 170 Itr. 19 Itr. 1 Itr.

Hydraulic system 25.9 U.S. gal.

Differential and final drive case (each side) 4.5 U.S. gal.

Torque converter and transmission 8.2 U.S. gal.

98 Itr. 17 Itr. 31.0 Itr.

4-3

SPECIFICATIONS

Bucket type

General Purpose Bolt-On Cutting Edge

Excavating Bolt-On Cutting Edge

Light Material Bolt-On Cutting Edge

SAE Bated

2.75 yd’

2.1 rn’

2.5 yd’

1.9 rn’

3.5 yd ’

2.7 mJ

Struck

2.35 yd’

1.8 ms

2.25 yd J

1.7 m3

3.0 yds

2.3 ms

Bucket Width

8’10”

2685mm

8’10”

2685mm

8’10”

2685 mm

Bucket Weight

2,172 Ibs

985 kg

2,106 Ibs

955 kg

2,415 Ibs

1095 kg

Bucket Capacity

Static Tipping Loads

Straight

19.338 Ibs 8770 ka

19,393 Ibs

8795 kg

19,040 Ibs 8635 kg

Full Turn

17,056 Ibs 7735 kg

17,111 Ibs

7760 kg

19,758 Ibs 7600 kg

Dumping Clearance, max. height and 45’ dump angle

9’2

2805 mm

9’4”

2835 mm

9’1”

2755 mm

Beach @ 7’, 2130 mm cutting edge clearance and 45” dump angle

4’10”

1465 mm

4’9”

1450 mm

5’0”

1520 mm

Reach at max. height and 45” dump angle

3’7”

1090 mm

3’5”

1050 mm

3’11”

1200 mm

Beach with arm horizontal and bucket level

7’1”

2165 mm

6’11”

2115 mm

7’8”

2330 mm

Operating Height

(fully raised)

16’1”

4910 mm

15’11”

4850 mm

16’9”

5100 mm

Overall Length

Bucket ground

23’2”

7070 mm

23’0”

7020 mm

23’9”

7235 mm

Bucket at carry

23’0”

7005 mm

22’7”

6870 mm

23’0”

7015 mm

18’10”

5740 mm

18’9”

5730 mm

19-o"

5790 mm

2.2”

55 mm

Turning radius (bucket at carry, outside corner of bucket) Digging Depth

0”

Breakout force

23,748 Ibs 10,770 kg

Operating Weight

25.424 Ibs 11.530 ka

NOTE: All specifications

l

4-4

are subject to change without notice.

All dimensions, weights and performance values based on SAE J-732C and J-7428 standards.

l

Static tipping load and operating weight shown include lubricant, coolant, full fuel tank, ROPS cab (option), 20.52512PR(L2) tires, hydraulic adapter kit, heater, ground driven steering, front fenders, additional counterweight and operator. Machine stability and operating weight are affected by counterweight, tire size and other attachments.

SPECIFICATIONS Add the following weight changes to operating weight and static tipping loads.

WEIGHT CHANGES Change in tipping

Change in Operating Weight

load

Full Turn

Straight -673 Ibs

-305 kg

-1565 Ibs

-710 kg

-1367 Ibs

-620 kg

-1103 Ibs

-500 kg

-1058 Ibs

-480 kg

-1003 Ibs

-455 kg

ROPS Canopy (instead of ROPS Cab)

-551 Ibs

-250 kg

496 Ibs

-225 kg

-474 Ibs

-215 kg

Bucket Teeth (instead of bolton cutting edge)

-232 Ibs

-105 kg

-287 Ibs

-130 kg

-287 Ibs

-130 kg

17.52512PR(L2)

tubeless tires

-551 Ibs

-250 kg

-397 Ibs

-180 kg

-353 Ibs

-160 kg

17.525_12PR(L3) tubeless tires

-309 Ibs

-140 kg

-276 Ibs

-125 kg

-254 Ibs

-115 kg

Additional Counterweight (removed) ROPS Cab (removed)

I

20.52512PR(L2)

tubeless tires

20.52512PR(L3)

tubeless tires

NOTE: All specifications

0

0 +353 Ibs

+160 kg

+221 Ibs

+lOO kg

0

+ 176 Ibs

+80 kg

are subject to change without notice.

4-s

SPECIFICATIONS

4’E

LOlAD

1 2 3 4 5

= = = = =

Operating Height Dumping Clearance Dumping Reach Overall Length Digging Depth Tires Tread Width over tires

A B C D

Wheel base 9’6” 2885 mn Hinge pin height, max. height 11’11 M 3632 mm Hinge pin height, carry position 1’3” 381 mm Ground clearance 1’7” 483 mm

20.5-25-l 2 PR(L2) 6’4” 1930 mm 8’1” 2464 mm

E F G

Hitch height Overall height, top of the stack Overall height, ROPS canopy

4’ 1219 mm 10'7" 3225 m

11’2”

3403 m-n

SPECIFICATIONS STANDARD STANDARD

TIGHTENING

TIGHTENING

TORQUE

TORQUES OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of this manual.

Thread diameter of bolt (mm)

Width across flat (mm)

Q

@

6 8 10 12 14

10 13 17 19 22

1.35kO.15 3.2kO.3 6.7kO.7 11.5~1.0 18.0?2.0

13.221.4 31.4k2.9 65.7k6.8 11229.8 177219

16 18 20 22 24

24 27 30 32 36

28.5? 3 39?4 5626 76*8 94.5? 10

279 I! 29 383 * 39 549 L 58 745 + 78 927 + 98

27 30 33 36

41 46 50 55 60

135?15 175a20 225 2 25 280 f 30 335 -c35

132Ok 140 1720t190 2210?240 2750 c 290 3280 f. 340

39

This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque. *

Nom (newton meter): 1 Nom %0.1 kgm

TIGHTENING

TORQUE

OF SPLIT

FLANGE

BOLTS

Use these torques for split flange bolts.

Tightening torque

Thread diameter of bolt (mm)

Width across flats (mm)

kgm

10 12 16

14 17 22

6.720.7 11.521 28.5 ?3

Nom 65.7k6.8 112k9.8 279229

4-7

SPECIFICATIONS TIGHTENING

TORQUE FOR NUTS OF FLARED Fll-l-INGS

Use these torques for nut part of flared fittings.

4-8

Thread diameter of nut part (mm)

Width across flats of nut part (mm)

kgm

Nom

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

2.5 +0.5 5?2 822 1423 18k3 2025 25+5 30+5

24.5 k 4.9 49k19.6 78.5� 19.6 137.3 t 29.4 176.5k29.4 196.1?49 245.2 249 294.2*49

Tightening

torque

SPECIFICATIONS

UNIT CONVERSIONS

4-9

SPECIFICATIONS

UNIT

I

MULTIPLY BY

TO GET

I

I

MULTIPLY BY

TO GET

I

AREA

I

square millimeter (mm2)

O.OlIl55wO3

square inch

6.4516

square centimeter (cm2)

0.1550003

square inch

0.00064516

square meter (m2)

square foot (f?)

0.09290304

square meter (m2)

square yard (yd2)

08361274

square meter (m2)

1.195990

square yard

square meter (m2)

0.03953686

square rod

645.16 square inch (in2)

25.29285

I

square inch

1550.003

square foot

10.76391

square rod (rod2) square hectometer

0.002529285 4046.856

(hm2)

square rod

395.3686

square meter (m2)

0.0002471054

acre

2.471054

acre

square meter (m2)

0.0000003861022

square mile

square kilometer (km2)

0.386102175

square mile

acre 0.4046856

square hectometer

2589988.0

(hm2)

square mile (mile2) 2589988

I

UNIT

I

MULTIPLY BY

I

DENSITY pound per cubic yard

0.5932763

16.01846

27.67990

(lb/in3)

Density)

kilogram per cubic meter

TO GET

I

1.685555

(tb/yd3)

kilogram per cubic meter

0.06242797

(fb/ft3)

gram per cubic centimeter

0.03612730

(lb/in3)

8.345406

(lb/US gal)

(g/cm3)

pound per US gallon (Ib/US gal)

0.1198264

pound per UK gallon (lb/UK gal)

0.09977633

4-10

(Mass

MULTIPLY BY

(kg/m3)

(fb/ft3) pound per cubic inch

I

(kg/m3)

(fb/yd3) pound per cubic foot

TO GET

10.02242

(lb/UK gal)

I

SPECIFICATIONS

UNIT

MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

FORCE pound, pound-force (lbf)

ounce-ounce-force

(ozf)

UNIT

4.448222

newton (N)

0.004448222

kilonewton

0.2780139

newton (N)

MULTIPLY BY

0.2248089 (kN)

TO GET

224.8089 3.596942

pound-force pound-force ounce force

MULTIPLY BY

TO GET

FORCE PER LENGTH 0.1751268 trx$ij

newton per millimeter (N/mm)

5.710148

pound-force

per inch

force per inch

pound-force (lbf/ft)

per foot)

UNIT

175.1268

newton per meter (N/m)

0.005710148

pound-force

per inch

14.5939

newton per meter (N/m)

0.06852178

pound-force

per foot

MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

HEAT British thermal unit (Btu)

Btu per hour* (E&u/h) Btu per minute* (Btu/min) Btu per gallon (Btu/gal)

1.055056 1055.056 0.2930711 17.58427 0.2787163

kilojoule (kj)

0.9478170

(Btu)

joule (J)

0.0099478170

(Btu)

watt (W)

3.412141

(Btu/h)

watt (W)

0.05686902

(Btu/min)

kilojoule per liter (kJ/I)

3.5878777

(Btu/gal)

*Heat flow rate. Also see POWER.

4-l 1

SPECIFICATIONS

MULTIPLY BY

UNIT

MULTIPLY BY

TO GET

TO GET

LENGTH

I inch (in)

I

I microinch

25.4

1 millimeter (mm)

2.54

centimeter

(cm)

0.0254

meter (m)

1

0.03937008 0.3937008 39.37008

( (in) (in) (in)

bin)

mile

MULTIPLY BY

UNIT

TO GET

MULTIPLY BY

TO GET

MASS (WEIGHT)

gram(9)

28.34952 ounce 0.02834952 grain

0.06479891 I

pound (lb)

0.03527397

(04

kilogram

35.27397

(oz)

gram (9)

15.43236

grain

1

0.4535924 907.1847

kilogram (kg)

2.204622

(lb)

kilogram (kg)

0.001102311

short ton

megagram

1.102311

short ton

kilogram (kg)

0.0009842064

long ton

megagram

0.9842064

long ton

short ton (2000 lb) 0.9071847 1016.047

(Mg)

long ton 1.016047

4-12

(Mg)

SPECIFICATIONS

UNIT

MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

POWER 0.7456999 horsepower

kilowatt (kW)

1.341022

(hp)

watt ON)

0.001341022

(hp)

watt ON)

3.412141

(Btu/h)

watt ON)

0.05686902

(Btu/min)

(hp) 745.6999

Btu per hour* @u/h)

0293cl711

Btu per minute* (Btu/min)

17.58427

*Also heat flow rate. Bee HEAT.

UNIT

MULTIPLY BY

TO GET

MULTIPLY BY

TO GET

6.894757 pound force per square inch (psi) kilogram force ersquare centimeter (kg Pcm ) kilogram force per square hentimeter (kg/cm 1

(psi)

kilopascal (kPa)

0.01019716

(kg/cm2)

inch of mercury (in Hg)

3.37685

kilopascal (kPa)

0.296134

(in Hg)

inch of water (in H20)

0.24884

kilopascal (kPa)

4.0186

(in H20)

kilopascal (kPa)

0.01

bar

I

bar

I

98.0665

14.225

100.0

UNIT

MULTIPLY BY

degree Fahrenheit (“F)

(OF-32) + 1.8

TO GET

degree Celsius (“C)

MULTIPLY BY

(1.8x”C)

+ 32

I I

TO GET

(“F)

I

4-13

SPECIFICATIONS

UNIT

MULTIPLY BY

TO GET

MULTIPLY BY

TO

GET

TEMPERATURE INTERVAL OR TOLERANCE degree Fahrenheit (“F)

divide by 1.8

UNIT

MULTIPLY BY

degree Celsius (“C)

TO GET

1.8

(“F)

MULTIPLY BY

TO GET

VOLUME cubic yard (yd3)

0.7645549

cubic meter (m3)

cubic foot (ft3)

0.02831685

cubic meter (m3)

16.38706

cubic centimeter (cm3)

1.307951

(yd3)

35.31466

(ft3) 3 (in )

0.06102376

cubic inch (in3) 0.01638706

liter (I)

3.785412

liter (I)

0.003785412

cubic meter (m3)

US liquid quart (US qt)

0.9483529

liter (I)

1.066688

(US qt)

US liquid pint (US pt)

0.4731765

liter (I)

2.113376

(US Pt)

cup

0.2365882

liter (I)

4.226753

cup

0.02957353

liter (I)

US liquid gallon (US gal)

61.02376 0.2641720 264.1720

33.81402

(in3)

.

(USW (US gal)

(US fl oz)

US fluid ounce (US fl oz)

tablespoon teaspoon

UK liquid gallon (UK gal)

29.57353

cubic centimeter (cm3)

0.03381402

(US fl oz)

14.78676

milliliter (ml)

0.06762807

tablespoon

4.928922

milliliter (ml)

0.2028841

teaspoon

4.546692

liter (I)

0.2199692

(UK gal)

0.004546092

cubic meter (m3)

0.02841307

liter (I)

219.9692 35.19507

(UK gal) (UK fl oz)

UK fluid ounce (UK fl oz) 28.41307

4-14

cubic centimeter (cm3)

0.03519507

(UK fl oz)

I

SPECIFICATIONS

UNIT

MULTIPLY BY

MULTIPLY BY

TO GET

TO GET

TORQUE pound-force foot (Ibf ft) or (ft lb)

1.366818

newton meter (Nom)

0.7376621

(Ibf ft) or (ft lb)

0.1383

kilogram-force meter (kgfom) or (kg-m)

7.233

(Ibf ft) or (ft lb)

I

pound-force inch (Ibf in) or (in lb)

(m/s)

inch per second (in/s) meter per second (m/s)

4-15

SPECIFICATIONS MEMORANDA

4-l 6

Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186

PROPOSAL

1

FOR MANUAL

REVlslON

FOR INTERNAL USE ONLY -- No. PMR 2

NAME OF COMPANY:

:

PHONE NO:

: S

DEPARTMENT:

E R

NAME:

MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:

PROBLEM:

Attach photo or sketch.

If more space is needed, use another sheet.

1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:

PFMRl 081696

LOCATION:

DATE: